1 SPF-001 (Rev.D1)

DOCUMENT RELEASE AND CHANGE FORMPrepared For the U.S. Department of Energy, Assistant Secretary for Environmental ManagementBy Washington River Protection Solutions, LLC., PO Box 850, Richland, WA 99352Contractor For U.S. Department of Energy, Office of River Protection, under Contract DE-AC27-08RV14800

TRADEMARK DISCLAIMER: Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof or its contractors or subcontractors. Printed in the United States of America.

Release Stamp

1. Doc No: RPP-8360 Rev. 06

2. Title:LIFTING ATTACHMENT AND LIFTED ITEM EVALUATION

3. Project Number: ☒ N/A 4. Design Verification Required:☐ Yes ☒ No

5. USQ Number: ☒ N/AN/A-4

6. PrHA Number Rev. ☒ N/A

Clearance Review Restriction Type:public

7. Approvals

Title Name Signature DateClearance Review BRATTON, GAYLA E BRATTON, GAYLA E 09/28/2017Checker MACKEY, TOM MACKEY, TOM 08/23/2017Document Control Approval PORTER, MARY PORTER, MARY 09/28/2017Originator MCSHANE, MICHAEL MCSHANE, MICHAEL 08/23/2017Responsible Engineering Manager KNIGHT, MARK A KNIGHT, MARK A 09/07/2017USQ Evaluator JONES, ROY (BUD) JONES, ROY (BUD) 08/23/2017

8. Description of Change and Justification

Existing requirements have been more clearly identified and explained. Compliance with this document is required as a flow-down from ASME NQA-1 2008/2009 Subpart 2.15.Attachment E was revised to provide generic requirements to be included in standard specifications.

9. TBDs or Holds ☒ N/A

10. Related Structures, Systems, and Components

a. Related Building/Facilities ☐ N/A b. Related Systems ☒ N/A c. Related Equipment ID Nos. (EIN) ☒ N/A

241G

11. Impacted Documents – Engineering ☒ N/A

Document Number Rev. Title

12. Impacted Documents (Outside SPF):

N/A

13. Related Documents ☒ N/A

Document Number Rev. Title

14. Distribution

Name OrganizationBINGHAM, JAMES D COGNIZANT SYSTEM ENGINEERINGCALL, LYNN ENGRNG PROGRAMS & STANDARDSHAQ, MIAN A WASTE STORAGE & TECH SUPPORT ENGINEERINGHULL, KEVIN J ELECTRICAL/AREA/242A-EVAP ENGHUNTINGTON, MATTHEW R MECHANICAL & HVAC ENGINEERINGKNIGHT, MARK A ENGRNG PROGRAMS & STANDARDSLAWRENCE, HUGH K INDUSTRIAL SAFETY PROGRAMMACKEY, TOM ENGRNG PROGRAMS & STANDARDSMCSHANE, MICHAEL ENGRNG PROGRAMS & STANDARDSPOWERS, DANIEL J WASTE TRANSFER ENGINEERINGPRINCE, ANDREW C WASTE STORAGE & TECH SUPPORT ENGINEERINGSCOTT, MARK A ENGRNG PROGRAMS & STANDARDSSWANEY, STEVE L C FARM RETRIEVAL & CLOSURETRESS, ERIC M DESIGN SERVICES

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Sep 28, 2017DATE:

A-6002-767 (REV 3)

RPP-8360, Rev. 06

LIFTING ATTACHMENT AND LIFTED ITEM EVALUATION

TC Mackey

MP McShane

Washington River Protection Services, LLC

Richland, WA 99352U.S. Department of Energy Contract DE-AC27-08RV14800

EDT/ECN: DRCF UC:

Cost Center: Charge Code:

B&R Code: Total Pages: 27

Key Words: Lifting Bail, Hoisting & Rigging, Cover Block, Lifting Point

Abstract: This dociment provides a guideline for the structural evaluation of permanently installed lifting points on tank farm components. It contains the required hoisting forces and guidelines foracceptance and qualification for use of lifting points for cover blocks and other tank farm equipment.

TRADEMARK DISCLAIMER. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof or its contractors or subcontractors.

Release Approval Date Release Stamp

Approved For Public Release

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By G. E. Bratton at 12:41 pm, Sep 28, 2017

Sep 28, 2017DATE:

A-6003-835 (REV 2)

Tank Operations Contractor (TOC)

RECORD OF REVISION

(1) Document Number:

RPP-8360 Page 1

(2) Title:

LIFTING ATTACHMENT AND LIFTED ITEM EVALUATION

Change Control Record

(3) Revision

(4) Description of Change – Replace, Add, and Delete Pages

0 Initial Release with EDT 631954

1 Incorporate changes made per ECN-663554

2 Incorporate changes made per ECN-666723

3 Incorporate changes made per ECN-722728-R0

4 Incorporate changes made per ECN-13-000191

5 Added background. Editorial changes. Clarified lifting attachments. Added field inspection format in Attachments B,C & D. Added wording to allow use by public. Added Load Handling references. Added Standard Specifications.

6 Complete revision and reorganization of all sections. Reformatted for additional clarity. Attachment for Standard procurement specifications.

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LIFTING ATTACHMENT AND LIFTED ITEM EVALUATION

Prepared by

T.C. MackeyM.P. McShaneWashington River Protection Solutions, LLC

Date RevisedAugust 2017

Prepared for the U.S. Department of EnergyOffice of River Protection

Contract No. DE-AC27-08RV14800

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CONTENTS

1.0 BACKGROUND .............................................................................................................. 1

2.0 INTRODUCTION............................................................................................................ 1

3.0 EVALUATION PACKAGE ........................................................................................... 2

3.1 Evaluation Package Contents ...................................................................................... 2

3.1.1 Engineering Drawings:......................................................................................... 2

3.1.2 Inspection Report Forms: ..................................................................................... 2

3.1.3 Structural Evaluation Report:............................................................................... 2

3.1.4 Hoisting, Rigging and Load Handling ................................................................. 3

4.0 ENGINEERING DRAWINGS ....................................................................................... 3

5.0 INSPECTIONS, REPORTS AND MAINTENANCE .................................................. 3

5.1 Inspection Guidelines .................................................................................................. 3

5.1.1 Cover Blocks/Cover Plates................................................................................... 3

5.1.2 Shield Plugs.......................................................................................................... 3

5.1.3 Lifting Attachments.............................................................................................. 3

5.1.4 Inspection for Special and Critical Lifts .............................................................. 4

5.2 Field Inspection ........................................................................................................... 4

5.3 Inspection Results/Documentation .............................................................................. 4

6.0 STRUCTURAL EVALUATION REPORT .................................................................. 4

6.1 Existing Calculations................................................................................................... 4

6.2 Special Considerations ................................................................................................ 5

6.3 Structural Analysis ...................................................................................................... 5

6.3.1 Background .......................................................................................................... 5

6.3.2 Format and Preparation ........................................................................................ 5

6.3.3 Method of Analysis .............................................................................................. 6

6.3.4 Non-Limiting Components .................................................................................. 8

6.3.5 Alternate Analysis Method................................................................................... 8

6.3.6 Allowable Stresses ............................................................................................... 9

6.3.7 Alternate Allowable Stresses/ Design Strength/ Allowable Strength .................. 9

6.4 Analysis Software........................................................................................................ 9

6.5 References Information ............................................................................................. 10

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6.6 Alternate Qualification Method for Bent Lifting Attachments ................................. 10

7.0 HOISTING, RIGGING AND LOAD HANDLING.................................................... 10

7.1 Required Information for Hoisting, Rigging and Load Handling ............................. 10

7.2 OTHER DESIGN CONSIDERATIONS................................................................... 11

7.2.1 Spacers ............................................................................................................... 11

7.2.2 Synthetic Slings.................................................................................................. 11

8.0 PROCUREMENT.......................................................................................................... 12

8.1 Standard Specification............................................................................................... 12

9.0 REFERENCES............................................................................................................... 13

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ATTACHMENTS

Attachment A: GUIDELINES FOR ACCEPTANCE AND QUALIFICATION FOR USE OF LIFTING ATTACHMENTS FOR COVER BLOCKS

Attachment B: STRUCTURAL INTEGRITY VERIFICATION OF LIFTING ATTACHMENTS

Attachment C: LIFTING ATTACHMENT FIELD REPORT BY ENGINEER

Attachment D: LIFTING ATTACHMENT FIELD INSPECTION REPORT BY QA

Attachment E: STANDARD SPECIFICATIONS

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LIFTING ATTACHMENT AND LIFTED ITEM EVALUATION,FOR HOISTING, RIGGING, TRANSPORT AND LOAD

HANDLING

1.0 BACKGROUND

The Hanford Site produced plutonium for use in World War II and during the “Cold War”.Production processes left solid and liquid wastes that posed a risk to the local environment including the Columbia River. A great deal of this waste is stored in a series of massive underground storage tanks.

The mission of the River Protection Project (RPP) is to store, retrieve, treat, and dispose of the highly radioactive waste stored in the Hanford Site tanks in an environmentally-sound, safe, and cost-effective manner. The tanks are supported by ancillary systems and equipment (e.g., transfer piping, valve pits), which allow the movement of the waste into, within, and out of the tank system. In order to ensure operation within Hanford tank farms, various pit covers and equipment must be hoisted, lifted or transported through the use of cranes and other equipment.These covers can be two to three feet thick concrete weighing as much as forty thousand pounds.

In the year 2000, an incident occurred while attempting to lift one of these concrete cover blocks. At that time there was no program in place to ensure the lifting attachments were adequate to lift the cover block. The Tank Operation Contractor has developed the necessary engineering, safety, and operations procedures to ensure safe lifts are performed. Thisengineering document, RPP-8360, was developed to control the design of both lifting attachments and lifted items, as well as provide lifting and load handling requirements.

2.0 INTRODUCTION

The objective of the processes described in this document are to ensure that all items to be lifted and their lifting attachments, can withstand the loads imposed by lifting operations withinacceptable margins of safety and that this information is properly and completely communicated to the hoisting and rigging organization. This document provides the evaluation methodology for inspection and design of both lifted items and lifting attachments as well as providing, load handling and procurement requirements for all hoisting and rigging related equipment. The requirements of ASME NQA-1 2008 and addendum 2009 (as applicable to hoisting and rigging) are also to be implemented in all hoisting, rigging, transport and load handling inspection and design.

Specifically defined are: inspection criteria, new or retrofitted lifting attachment design requirements, and lifted item design requirements. Evaluation and maintenance processesinclude permanently installed, and temporarily installed lifting attachments (both existing and new). This evaluation process ensures that the lifted item is structurally adequate and willidentify any modifications to the lifted item including additions as documented on the original

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drawings. The lifting attachment design process also ensures the design includes the ability to safely remove an item from a facility at the end of its design life.

An Evaluation Package will be generated for each item covered by this program. The evaluation package will include: engineering drawings, completed inspection report forms, structural evaluation report, and inspection documents needed to qualify lifting attachments on the item for lifting. Evaluation Packages shall be assembled, maintained, and controlled by the Tank Operating Contractor (TOC). Maintenance information, if applicable, will be tracked through an approved Maintenance Program and any required corrective maintenance will be tracked through an approved Corrective Maintenance Program.

3.0 EVALUATION PACKAGE

3.1 Evaluation Package Contents

Evaluations administered by this program shall be documented using an evaluation package accurately capturing the current configuration and physical condition of both a lifted item and any lifting attachments. Upon completion, the Evaluation Package will be uploaded into the Integrated Document Management System (IDMS) Lifting Point Database by the TOC Engineer. The evaluation package shall include the following, as a minimum:

3.1.1 Engineering Drawings:

Current drawings and applicable Engineering Change Notices (ECN’s) that include information relevant to the existing condition, configuration, loading, and construction of the lifted item or lifting attachments. Note any changes or modifications made to the item(s) suchas penetrations or added components. Engineering Drawings are further discussed in Section 4.0.

3.1.2 Inspection Report Forms:

A record of the “as-found” configuration of the item, together with an assessment of the condition of the lifting attachments. Information recorded in the inspection report will be used to determine whether the inspected lifting attachment can be: used as-is, repaired prior to use, qualified by load testing, removed from service, or replaced with a new lifting attachment.Additional information and specific details of Inspection Reports and Maintenance are found in Section 5.0.

3.1.3 Structural Evaluation Report:

The Structural Evaluation Report shall analyze and evaluate the load capacity and the integrity of the lifted item(s) and lifting attachment(s). Accurate information from the engineering drawings and applicable information from the inspection reports will be used to complete a structural analysis/calculation described in section.

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3.1.4 Hoisting, Rigging and Load Handling

This section of the Evaluation Package summarizes the information gathered and calculated in the other sections. It also provides additional requirements for devices used to distribute lifting forces to a lifting attachment (i.e. spacers, slings, spreader beams, etc.) This information is used to communicate the requirements to the Hoisting and Rigging organization and should be in the form of a lift plan or lifting instructions.

4.0 ENGINEERING DRAWINGSEngineering drawings are used to determine the weights of the specified items(s), materials of construction, and specific design configurations to be considered in the evaluation. All applicable drawings together with any unincorporated ECNs must show any changes, additions or modifications to the original configuration which may include modifications or additions to the configuration in the evaluation. Following the evaluation process, if the item is to be used at a later date, the drawings and associated design media shall be revised, either by ECN or by direct revision, to reflect both the “as-found” conditions discovered during inspection, and the necessary repairs and/or modifications required as a result of the inspection findings.

5.0 INSPECTIONS, REPORTS AND MAINTENANCEA field inspection is to be performed for each item (eg. cover block, cover plate, shield plug, equipment) with its associated lifting attachments. The TOC and subcontractors shall inspect as required by procedure TFC-ENG-DESIGN-D-37. An inspection report is then prepared, detailing existing field conditions including any changes, modifications or additions to the original configuration. The inspection process is an input for analysis, and by itself, does not determine if a lifting attachment is adequate. Maintenance information, if applicable, will be tracked through an approved Maintenance Program and any required corrective maintenance will be tracked through an approved Corrective Maintenance Program. 5.1 Inspection Guidelines

5.1.1 Cover Blocks/Cover Plates

All cover blocks/cover plates with permanent lift attachments should be inspected using the guidance in Attachments A and B.

5.1.2 Shield Plugs

All shield plugs shall be inspected and evaluated using methodology determined by the engineer.

5.1.3 Lifting Attachments

Lifting attachment inspections shall be performed using a graded approach. Attachments A and B to this document include guidelines for engineering acceptance and qualification of the lifting attachments. Attachments C and D provide inspection criteria for physical evaluation of the lifting attachment. Using these guidelines, engineering shall determine whether the lifting

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attachment can be used as-is, needs to be repaired, should be qualified by load testing, or should be removed from service.

5.1.4 Inspection for Special and Critical Lifts

The TOC and its subcontractors when performing critical and special lifts, as discussed in procedure TFC-ENG-FACSUP-C-25, Hoisting and Rigging, shall have the lifted item and its lift points verified as adequate.

5.2 Field Inspection

An inspection report shall be completed using the format provided in Attachment C or D. The inspection process shall record the physical condition of all existing lifting attachments for evaluation by comparison to design or calculated limits and dimensions.

Additional inspection or Non Destructive Examination (NDE) may be required, if deemed necessary by engineering. All additional inspection and/or NDE results should be noted and filed with the corresponding Lifting Attachment Field Inspection Report.

5.3 Inspection Results/Documentation

If the lifting attachment inspection results show significant differences from the drawings, i.e., smaller cross section area, different configuration and/or dimensions, etc., and/or does not satisfy the acceptance guidelines of Attachment A or B, the actual dimensions from field inspection shall be used in the structural evaluation (see Section 6.0). When significant differences between the drawings and the as-found conditions exist, the engineer shall be responsible for revising the engineering drawings by ECN/DCN to reflect the current “as-found” conditions if the component is to remain in service. This ECN/DCN shall identify the item being lifted. The engineer shall determine all preventive and/or corrective maintenance actions for the item being lifted.

6.0 STRUCTURAL EVALUATION REPORT

This evaluation is used to make recommendations concerning a lifted item and/or lifting attachments. An evaluation must be on record for initial use, continued use, replacement, modification, and/or repair.

All engineering calculations should follow the guidelines provided in American Society of Mechanical Engineers (ASME) NQA-1 “Quality Assurance Requirements for Nuclear Facility Applications”. TOC and its contractors shall follow procedure TFC-ENG-DESIGN-C-10 Engineering Calculations with any and all documentation released according to requirements of procedure TFC-ENG-DESIGN-C-25 Technical Document Control.

6.1 Existing Calculations

An existing calculation can be used by reference under the following circumstances: if the lifting attachment condition and item configuration is similar to an existing evaluation, or if ithas not changed since a previous inspection. The structural evaluation report shall be used to

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plan proposed lifting operations, and shall contain the hoisting and rigging information required by Section 7.0 of this document.

6.2 Special Considerations

Design of the equipment to be lifted, the procurement specifications, and procurement documents should identify requirements to transport the equipment in such a manner that the orientation of the lift attachments are easy to access and facilitate lifting. The equipment should not have to be re-oriented prior to lifting.

All equipment requiring load handling for placement in a Tank Farm or inside a waste tank shall have a lift attachment evaluation containing provisions for equipment removal.

During the removal of radiologically contaminated Long Length Equipment (LLE), it is common to wrap the equipment in plastic to control contamination. Past practice has required installing a clamp on the lower end of the LLE as a tail crane attachment. The clamp is placed over the plastic to prevent the choke hitch from slipping when the LLE is rotated from the vertical to the horizontal position. The installation of the clamp exposes the workers to contamination. When traditional lift attachment design, e.g. lifting lugs, hoist rings, etc., is not feasible, e.g. due to a contamination issue, designers shall have a designed flange, indentation, or other stop mechanism to prevent the lower sling choke hitch from slipping. Load rated sling cut protection shall be required for this application.

All non-analyzed shield plugs with a permanently installed steel U-bar should be lifted using a spacer (H-2-830454, “Standard Spacer for Lifting Bails”).

6.3 Structural Analysis

The structural analysis will determine the structural integrity, the Maximum Allowable Rated Capacity, and the Recommended Not-To-Exceed Lifting Pull (per lifting attachment or cover) as described below.

6.3.1 Background

This process was originally based on the “Manual of Steel Construction, Allowable Stress Design,” American Institute of Steel Construction (AISC, 1989) using the Allowable Stress Design (ASD) method. The more current versions of the AISC incorporate the Load and Resistance Factor Design (LRFD) process. The use of LRFD is acceptable provided the same factors of safety are equivalent to or better than the results obtained by using the ASD method.

6.3.2 Format and Preparation

The TOC and subcontractors shall use the guidelines and forms presented in procedures TFC-ENG-DESIGN-C-10 and TFC-ENG-DESIGN-D-37. The design agent shall prepare, check, and document the analysis to the requirements of this section and comply with TFC-ENG-STD-06.. The guidelines of ASME NQA-1 and forms presented in the Attachments should be used. The analysis shall be legible and reproducible. Calculation methods shall be documented to the extent that the checker can repeat the calculation and reach the same conclusion without contacting the analyst. The approved calculation shall then be included in the Structural Evaluation Report Package.

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The analysis shall follow TFC-ENG-DESIGN-C-10 Attachment A – Calculation Format and Preparation Instructions.

6.3.3 Method of Analysis

This analysis method is to be used in the calculation to provide the information necessary to communicate info needed for lift instructions. If any step is not used, indicate so and provide justification.

1. Estimated Weight of item:

Determine the dead weight of each item by calculation, or (if available) from the indicated weight of a calibrated load measuring device. For reference, describe how the weight information was obtained. If weights are determined from drawings, the drawings must reflect the current configuration.

2. Weight Contingency Factor:

If a measured weight is available, it may be used without a contingency increase. If an actual measured weight is not available, increase the estimated weight from Step 1 by a reasonable contingency factor to account for uncertainty and potential differences between the reference drawings and actual field conditions. The recommended increases are: a) 15% or more, for vessels, pumps, and other items with voids that may contain liquid, b) 5% for items that are solid or for which void-fill is already accounted for in the estimated weight, c) as much as 25% to account for additional concrete stuck to the underside of pits and vaults.

3. Dynamic Lifting Force:

Increase the resultant weight from Step 2 by 25% to account for dynamic loads from crane operations. In special circumstances, the dynamic load may be controlled to less than 25%. Such circumstances must be established in Step 9.

4. Design Weight:

The weight to be used in the structural analysis is the resultant weight after applying the contingency factors in both step 2 and Step 3 In most cases, the Design Weight is the Estimated Weight (from Step 1) multiplied by (1.05) and then multiplied by(1.25). The resultant Design Weight may be used in subsequent lift plans as the Recommended Not-to-Exceed (RNTE) value.

5. Material Properties:

Utilize appropriate technical references (i.e. American Society for Testing and Materials (ASTM) standards), and provide reference to sources in calculations.

6. Evaluation of Stresses:

Use the requirements of the appropriate code and/or standard for evaluating the lifted item and its lifting attachments. Examples include: For steel structures, ANSI/AISC360 Specification for Structural Steel Buildings (AISC Specification) and the AISC Steel Construction Manual(AISC Manual). For concrete structures, the American Concrete Institute (ACI) codes (i.e., ACI 349, Code Requirements for Nuclear Safety-

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Related Concrete Structures, and ACI 318, Building Code Requirements for Reinforced Concrete.)

a) Use Design Weight calculated in Step 4 above.

NOTE - When Actek hoist rings are used, reference Vendor Information File 50159, Hoist Rings when populating the “Related Documents” tab in SmartPlant® Foundation.

b) Use 90% of theoretical lifting attachment (as shown on drawings) area and equivalently reduced section modulus to account for corrosion where found.Note: For Swivel Hoist Rings use Manufacturer’s rating.

NOTE - A sling angle of less than 60 degrees from horizontal may be used as needed (such as in applications where head room is limited) However, an angle of less than 45 degrees must be approved by the Hoisting and Rigging SME.

c) Determine the sling angle to be used in the analysis. This angle is to be shown on both the drawings and lift points of the lifted item. Listing the minimum sling length required to maintain the specified sling angle is also required. As a standard practice for items with two or more lifting attachments, a sling angleof 60 degrees (from horizontal) or greater is used to reduce the lateral load component.

NOTE - Item d below is applicable only if the weight is evenly distributed to the multiple lifting attachments. Always determine adequacy of lifting attachments based on the forces and their distribution (vertical, horizontal and resultant loads) as appropriate.

d) Determine the force per lifting attachment. In the case of multiple lifting attachments, divide the Design Weight from Step 4 above by the number of lifting attachments at the angle specified. For items with 2 or 3 lift attachments,distribute the load evenly between the lift points. If there are 4 lifting attachments, distribute the load among 3 of them.

e) Determine adequacy of concrete items for shear cone pullout at the lifting attachment, and for bending capacity of the item if appropriate.

f) Determine adequacy of welds.

7. Design Ratio:

Determine the design ratios for the resultant stresses in each analyzed component. The design ratio is the allowable stress divided by the calculated stress. If the design ratio is greater than 1, move on to the next step.

A design ratio of less than 1 requires any of the following: perform a more detailed analysis, modify/repair/ replace the lifting attachment, or change the lifting method.The revised analysis and/or the analysis for the repaired/replaced lifting attachmentshall be included in the Evaluation Package. Non-limiting components, as described in Section 6.3.4, may have a design ratio less than 1, and in such cases, shall not be used to calculate a capacity.

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NOTE- The Maximum Allowable Rated Capacity includes design and impact factors. The maximum allowable dead weight is the Maximum Allowable Rated Capacity divided by the design and impact factors.

8. Maximum Allowable Rated Capacity:

Determine the Maximum Allowable Rated Capacity by multiplying the Design Weight from Step 4 with the minimum design ratio obtained in Step 7. (See Section 6.3.4 for non-limiting components).

9. Recommended Not-To-Exceed Lifting Pull:

Determine a Recommended Not-To-Exceed Lifting Pull for each lifting attachment and for the entire item. This is primarily for items that may be stuck in place and therefore is not required for installing new items or for items that are not expected to be stuck.

The NTE is a safety limit, and is not based on the capacity of either the item or the lifting attachments. It may be as high as, but should never exceed the Maximum Allowable Rated Capacity determined in Step 8 or as low as the resulting weight from Step 2. In this case the dynamic lifting forces normally accounted for in Step 3, must be controlled by hoisting and rigging practices. Normally the Recommended Not-To-Exceed Lifting Pull is 1.25 times the Estimated Weight (Step1).

6.3.4 Non-Limiting Components

A component with the lowest design ratio may not be the limiting (governing) component in determining capacity. The rated capacity should not be based on components that normally are considered to be non-limiting (in some cases it may need to be considered to estimate the capacity). The following are examples of non-limiting conditions:

1. High local stresses in a computer model may be considered singularities and do not govern the design ratio. High local stresses however should be evaluated due to the potential to initiate a crack in the metal especially in cold weather conditions.

2. If a local contact bearing stress (Hertz stress) occurs between two components, it will produce local plastic deformation but will not result in a failure mode; thus, it may not be considered a limiting condition (e.g., local contact stresses between lifting attachment and hook or spacer).

3. High local concrete bearing stress at the base of the lifting attachment (due to in-plane bending of the bail at the concrete surface) will not result in a failure (because concrete shear off is the controlling failure mechanism); thus it may not be considered a limiting condition.

6.3.5 Alternate Analysis Method

An alternative analysis method may be used in certain instances. Such use requires the approval and signature of a Qualified Engineering Discipline Lead. Loading criteria outlined in section 6.3.3, and alternate allowable stresses in section 6.3.7 shall be used for these alternate analyses.

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6.3.6 Allowable Stresses

The computed stresses shall satisfy the requirements of the applicable codes and standards appropriate for the system being designed. The AISC Specification and AISC Manualrequirements and recognized references are used for the steel structures evaluation. The ACI349, Code Requirements for Nuclear Safety-Related Concrete Structures, or ACI 318, Building Code Requirements for Reinforced Concrete, are used for the evaluation of concrete structures.The Hanford Site Hoisting and Rigging Manual (HSHRM) (DOE-RL-92-36) is used for the evaluation of components that may be considered to be part of the hoisting and rigging system(i.e. below-the-hook lifting devices and/or spacers).

NOTE- The allowable stresses used to calculate the design ratio may differ from those stated in 6.3.6.1, 6.3.6.2, and 6.3.6.3. They may be modified, as applicable, based upon the criteria outlined in Section 6.3.7.

6.3.6.1 Steel Design Strength

The design strength for structural steel shall be specified by using the applicable revision of the AISC Specification and AISC Manual. However, ASME BTH-1 should be used to analyze holes on lifting attachments designed for use with shackles.

6.3.6.2 Concrete Design Strength

Concrete design strength shall be determined using the Building Code Requirements for Structural Concrete (ACI 318) listed in the “Reference Standards” section of the IBC.

6.3.6.3 Hanford Site Hoisting and Rigging Manual DOE-RL-92-36 (HSHRM) Allowable Stress

Below-the hook lifting devices (i.e., spreader beams) are governed by DOE-RL-92-36. ASME BTH-1 and ASME B30.20, Below-the-Hook Lifting Devices, shall be used for the design of below the hook lifting devices. All BTH lifters shall be load tested in accordance with ASME B30.20.

6.3.7 Alternate Allowable Stresses/ Design Strength/ Allowable Strength

The allowable stresses, design strength, and/or allowable strength used for lifted item and lift attachment analysis may be modified under certain circumstances. Under these special conditions, an evaluation process other than the one presented in this document may be necessary and is allowed. These conditions may include, but are not limited to: one-time liftswhere a lifting attachment will not be reused in tank farms, and work in high hazard/contamination areas. In all circumstances, this evaluation shall be performed by a qualified engineer using rational analysis in accordance with well-established principles. If an alternate design method is used, TOC and subcontractors shall have the approach reviewed and approved by a qualified Engineering Discipline Lead.

6.4 Analysis Software

A quality assurance plan should govern use of computer programs in the analysis by the performing organization. Checking the computer program results is the responsibility of the engineer and the analysis package checker. Computer software for TOC and subcontractorsshall satisfy the requirements provided in TFC-ENG-DESIGN-C-10 and ASME NQA-1.

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6.5 References Information

References should include the title, author or company, revision number or publication date,and address (if available). Reference format shall be documented in accordance with TFC-BSM-AD-STD-02, Editorial Standard and Format Guidance for Documents.

6.6 Alternate Qualification Method for Bent Lifting Attachments

An existing bent lifting attachment can be qualified as described in Section 6.3, or if it can be shown to have an adequate design margin by an alternate qualification method, e.g., by the testing approach described in RPP-9551, Qualification Test of the Bail Repair Assembly and Bail Load-Testing.

7.0 HOISTING, RIGGING AND LOAD HANDLING

This section of the Evaluation Package summarizes and provides the requirements for communicating information to the Hoisting and Rigging organization. It also provides additional requirements for devices used to distribute lifting forces to a lifting attachment (i.e. spacer discs, slings, spreader beams, etc.).

Load handling activities require positive control of load throughout the entire process of load movement. Hoisting, Rigging and Load Handling on the Hanford site requires adherence to RPP-8360, TFC-ENG-DESIGN-D-37, TFC-ESHQ-S-STD-28, Hoisting and Rigging Safety, TFC-ENG-FACSUP-C-25 Hoisting and Rigging, DOE-RL-92-36 and NQA-1 and mayadditionally require the use of DOE-RL-92-36; ASME P30.1, Planning for Load Handling Activities, or other standards and procedures as applicable.

7.1 Required Information for Hoisting, Rigging and Load Handling

The required information for hoisting, rigging and load handling in the Evaluation Package is a summary of the information gathered from the drawings, inspection(s) and analysis. The lifting devices needed should also be determined. This information will be used in lift planningand should include the following at a minimum:

1. Item identification and location (including the tank farm).

2. Number of items to be lifted.

3. If one or more items are to be lifted, identification of required sequences (e.g., if cover blocks are being lifted, identification of the "key" cover block and the “captive” cover block, and any required lift sequences.)

NOTE - If the weight of the item has been estimated, during the initial lift of an item, the dead weight should be measured and recorded on a calibrated measuring device (e.g. dynamometer). The item should be tagged with its weight. (If the item is being removed for disposal, establishing a record of the items weight is not necessary).

4. The weight of each item.

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NOTE - This is neither the lifting attachment capacity nor the failure load.

5. The Recommended Not-To-Exceed Lifting Pull (established in the structural analysis) to be applied to each lifting attachment and or lifted item. Engineering must be consulted in order to go above the Recommended NTE amount.

6. The spacing between lifting attachments.

7. A statement as to whether spreader beams or other load distributing devices are required.

8. Identification of the requirements for lifting attachment spacer(s) or other attachment devices.

9. Identification of any requirement for particular shackles (e.g., pin size, throat opening).

10. A statement by the analyst, if requested, noting that dynamic loading from crane operations shall be avoided, and that Hoisting and Rigging shall take actions to limit dynamic loads.

7.2 OTHER DESIGN CONSIDERATIONS

7.2.1 Shackles

Shackles shall be chosen based on required capacity and load configuration. Selected shackles should have 80 percent of the pin surface in contact with the lift point. Other devices, such as spacers may be needed to distribute the area of the shackle pin.

7.2.2 Spacers

Lifting attachment spacers are to be used to distribute the load on the lifting attachment inside radius.

If spacers are required:

1. Use Standard Spacer details as shown on Drawing H-2-830454, Spacers for Lifting Bails or, prepare and release ECNs as required for fabrication of non-standard lifting attachment spacers.

2. Match the spacer radius to the radius of bend in the lifting attachment or as otherwise determined in released calculations.

3. Use a trough or shims as needed to secure the lifting attachment from excessive lateral movement.

4. Call out the size, brand and type of shackle to be used; verify all rigging clearances.

5. The hole diameter of the lifted item shall meet the requirements of ASME BTH-1.

6. To the degree possible, locate the pin hole in the center of the lifting attachment.

7.2.3 Transport Tie-Downs

Separate calculations are required for the design of all transport tie-down attachment points. Lift points shall not be used for transport tie-downs.

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7.2.4 Synthetic Slings

When synthetic slings are used, call out the following as a minimum:

1. Width of sling

2. Number of Layers

3. Capacity of sling

4. Sling cut protection requirements. Specify “load rated” cut protection manufactured foruse in the configuration it is to be applied. Examples of applications requiring manufactured cut protection are: synthetic slings wrapped around edges, corners or when the sling is in contact with rough surfaces.

5. Specify load rated cut protection (softeners) when synthetic slings are used in applications where synthetic slings are in contact with a surface not specifically designed for use with synthetic slings.

8.0 PROCUREMENT

8.1 Standard Specification

All procurement specifications or statements of work should use Attachment E as a templatein writing specifications.

For General Service SSCs, the manufacturer may utilize the Standard Specifications for hoisting and rigging located in Attachment E, or provide lifting instructions proprietary to the manufacturer. Lift instructions shall include lift point locations and where to lift the item. Calculations on the lift points may be required for custom made equipment. Calculations must be provided for Special or Critical lifts.

DOE-RL-92-36, RPP-8360, and TFC-ENG-STD-06 shall be used where applicable to the design of the any equipment or items requiring load handling.

All crane and rigging shall be in accordance with DOE-RL-92-36 the Hanford Site Hoisting and Rigging Manual, and WRPS Procedures. Additional requirements of NQA-1 for Nuclear Plants and Nuclear Facilities may be required depending on the safety designation for the project. This could include the requirements to comply with ASME NUM-1: Rules for Construction of Cranes, Monorails, and Hoists (With Bridge or Trolley or Hoist of the Underhung Type) and ASME NOG-1 Rules for Construction of Overhead and Gantry Cranes (Top Running Bridge, Multiple Girder) code compliance for cranes.

The requirement of NQA-1 2008 and addendum 2009 shall be applied to all hoisting and rigging equipment and related procurements. The Rigging Engineer will use a graded approach in the selection of rigging hardware. At a minimum, Quality Level 3 (QL-3) mustbe used for all hoisting and rigging procurements. BTH lifters, rigging equipment, slings, hardware, etc. used for critical lifts may need to be procured to QL-2 or possibly QL-1.

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9.0 REFERENCES

Referenced codes, standards, and/or documents listed herein may not have year or revision specified; year or revision should be inferred as the latest version accepted at the time of the evaluation process.

ACI 318, Building Code Requirements for Reinforced Concrete, American Concrete Institute, Farmington, Michigan.

ACI 349, Code Requirements for Nuclear Safety-Related Concrete Structures,” American Concrete Institute, Farmington, Michigan.

AISC, Specification for Structural Steel Buildings, American Institute of Steel Construction, Chicago, Illinois.

AISC, Steel Construction Manual, American Institute of Steel Construction, Inc., Chicago, Illinois.

ASME B30.20, Below-the-Hook Lifting Devices, American Society of Mechanical Engineers, New York, New York.

ASME BTH-1, Design of Below-the-Hook Lifting Devices, American Society of Mechanical Engineers, New York, New York.

ASME NOG-1, Rules for Construction of Overhead and Gantry Cranes (Top Running Bridge, Multiple Girder), American Society of Mechanical Engineers, New York, New York.

ASME NQA-1 2008 and addendum 2009, Quality Assurance Requirements for Nuclear Facility Applications, American Society of Mechanical Engineers, New York, New York.

ASME P30.1, Planning for Load Handling Activities, American Society of Mechanical Engineers, New York, New York.

ASTM, Annual Book of ASTM Standards, American Society for Testing and Materials, West Chonshocken, Philadelphia, Pennsylvania.

DOE-RL-92-36, Hanford Site Hoisting and Rigging Manual, U. S.Department of Energy-Richland Operations Office, Richland, Washington.

H-2-830454, Standard Spacer for Lifting Bails, Rev.2, U. S. Department of Energy-Office of River Protection, Richland, Washington.

RPP-10975, Simplified Lifting Bail Evaluation Process, CH2M Hill Hanford Group, Inc., Richland, Washington.

RPP-16330, Standard Lifting Point Rated Load Capacities, CH2M Hill Hanford Group, Inc., Richland, Washington.

RPP-9514, Bail Repair and Load Testing, Numatec Hanford Company, Richland, Washington.

RPP-9551, 2002, Qualification Test of The Lifting Bail Repair Assembly And Lifting Bail Load-Testing, Numatec Hanford Company, Richland, Washington.

TFC-ENG-DESIGN-C-06, Engineering Change Control, Washington River Protection Solutions, LLC, Richland, Washington.

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TFC-ENG-DESIGN-C-10, Engineering Calculations, Washington River Protection Solutions, LLC, Richland, Washington.

TFC-ENG-DESIGN-D-37, Structural Integrity Verification of Lifting Points, Washington River Protection Solutions, LLC,, Richland, Washington.

TFC-ENG-DESIGN-C-25, Technical Document Control, Washington River Protection Solutions, LLC, Richland, Washington.

TFC-ESHQ-S- STD-28, “Hoisting and Rigging Safety”, Washington River Protection Solutions, LLC, Richland, Washington.

TFC-ENG-STD-06, “Design Loads for Tank Farm Facilities,” Washington River Protection Solutions, LLC, Richland, Washington.

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ATTACHMENT A

GUIDELINES FOR ACCEPTANCE AND QUALIFICATION FOR USE OF LIFTING ATTACHMENTS FOR COVER BLOCKS

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GUIDELINES FOR ACCEPTANCE, QUALIFICATION, AND USE OF LIFTING ATTACHMENTS ON COVER BLOCKS

1.0 SCOPE

This document provides recommendations for qualification and use of permanently installed lifting attachments. It includes requirements for inspection, maintenance, testing, and quality assurance. Also, see RPP-9551, current revision, for additional details on testing.

2.0 INSPECTION

Inspection should be made in accordance with the inspection requirements related to cover blocks and lifting attachments as stated in Attachments A and B. TOC and subcontractors shalluse TFC-ENG-DESIGN-D-37.

2.1 INSPECTION ITEMS

Quality Assurance should inspect for the following items and all findings should be documented by Lifting Attachment Field Inspection Report by QA Attachment D, hereinafter referred to as the “QA inspection report”. TOC and subcontractors should use Quality Assurance (QA) Site Form A-6003-765 (which matches Attachment D). Inspection findings not already documented in a specific section of the QA inspection report, should be documented inParagraph 5.0 of the QA inspection report, “Comments or Other Observations”. Common observations may include:

1. Deformation or distortion, such as bending, twisting, and ovality.

2. Wear.

3. Corrosion.

4. Cracks, nicks, or gouges.

5. Cracks and spalling in concrete around embedment.

6. Non-conformance to applicable engineering drawings, i.e., configuration, dimensions, etc.

Lifting attachments and securing means (if any) should also be inspected in accordance with the applicable sections of this document.

2.2 SCREENING ACCEPTANCE GUIDELINES

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This evaluation is to determine whether the lifting attachment:

1. Can be used as is

2. Needs to be repaired

3. Should be qualified by load testing

4. Should be removed from service

Any lifting attachment that has, one or more of the following indications of damage should be appropriately evaluated by engineering:

1. Deformation: Any bending or twisting, e.g., 5 degrees out of plane of the original unbent lifting attachment (see Figure 1).

2. Distortion: Any distortion causing ovality in the rounded portion of the lifting attachment.See Figure 2 for typical distortion of a lifting attachment.

3. Local plastic deformation: Any local plastic deformation (especially in square or rectangular bar) in which the section modulus is reduced in the plane of the curved radius of the lifting attachment (see Figure 3). This may occur when a circular hook or sling is wrapped around a rectangular lifting attachment (i.e., any lifting attachmentmaterial with sharp corners).

4. Wear: Any wear that causes a reduction in the inspected cross section area exceeding 10 percent of the original cross section area. Reduction in area of either the lifting attachment or its load pin (if any), i.e., dmeasured ≤ 0.90 ddesign , where ‘d’ is either an average diameter of round lifting attachment material or an average cross flat dimension of rectangular lifting attachment material.

5. Corrosion: Any surface corrosion, other than obviously superficial rust, may be removed and the corroded area may be cleaned to bare metal during lifting attachment field inspection activities. The remaining un-corroded metal should satisfy the section requirement provided in item 4, above.

6. Damage: Any cracks, nicks, or gouges that are visible on the bare metal after removal of the corrosion layer (see item 5, above), or that are visible on other non-corroded surfaces.

7. Concrete damage: Any cracks exceeding 0.013-inches in width on the surface of the surrounding concrete (Ref: ACI 318-95, Section R10.6.4 - Commentary) current code will allow for .016, or any other significant concrete spalling noted.

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2.3 EVALUATION AND ASSESSMENT OF LIFTING ATTACHMENTS FOR USE

Lifting attachments that show indications similar to those provided in the screening acceptance guidelines (section 2.2) or do not otherwise conform to the design drawings, should be evaluated (upon engineering request). The following items need to be satisfied for qualifying lifting attachments for use:

1. Dimensions of the existing lifting attachment cross section (diameter or cross flat dimension of rectangular section) should be recorded and should meet either the cross section requirements in Sections 2.2 and 3.0, or an analysis should be performed to evaluate the lifting attachment for use with its existing dimensions.

2. Structural analysis and stress evaluation should be performed to verify the “Recommended Not-To-Exceed Lifting Pull” of all lifting attachments, including an evaluation of the concrete cover block with all existing documented cracks. In addition, all repaired lifting attachments should be evaluated and re-load tested as necessary per RPP-9551.

3. Engineering should determine if additional lifting attachment radiographic or ultrasonic inspections should be performed.

3.0 MAINTENANCE AND REPAIRS

1. Any adverse conditions disclosed by the inspections performed in accordance with Section 2.2 should result in removal of the affected lifting attachment from service until it is evaluated by engineering for either continued use or corrective actions by either repair or replacement. The evaluation should be approved in accordance with TFC-ENG-DESIGN-C-10.

2. Engineering should determine whether NDE, i.e., radiographic or ultrasonic inspections, etc., should be performed before and after repair at all locations where damage is indicated, e.g., plastic deformations, cracks.

3. Surface Repairs:

3.1. Repairs of cracks, nicks, gouges, and corroded surfaces should be performed by using blending motions that follow the contours of lifting attachment materials. Lifting attachment cross-section dimensions should not be reduced more than 10 percent of the original dimensions.

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3.2. Repair cracks and spalls in concrete surfaces to restore strength and/or to prevent corrosion of embedded reinforcement bars.

4. Qualified staff should perform all repairs.

5. Replacement parts should, at a minimum, meet the strength and material property specifications of the original parts.

6. A structural analysis should be performed to determine the load capacity (rated load) of as-found, repaired, or replaced lifting attachments before use.

7. The repaired lifting attachment may require a new load test as described in Section 4.0.

8. The lifting attachment may be re-painted before use to reduce the potential of corrosion.

4.0 LOAD TESTING

Determine if altered, repaired, damaged, and modified lifting attachments should be load testing prior to use per RPP-9551. The decision to perform a load test should be made by engineering, and any load test plan should be approved by engineering prior to performance.

For existing lifting attachments, engineering should determine both the safe test load and the load test duration.

All load tests should follow the process presented in RPP-9551.

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5°

Figure 1: Bail Bent Out of Plane.

Figure 2: Bail Ovality.

Figure 3: Local Plastic Deformation of Rectangular Cross-Section.

After localplasticity

Original shape

DesignedRadius

MeasuredRadius

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ATTACHMENT B

STRUCTURAL INTEGRITY VERIFICATION OF LIFTING

ATTACHMENTS

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PURPOSE AND SCOPE

This guidance document describes the process used to ensure the structural integrity of lifting attachments. A lifting attachment is any permanently mounted apparatus e.g., lifting bail, lifting eye, on equipment, e.g., cover blocks, cover plates, and shield plugs. This guidance document also details the responsibilities of and steps to be taken by the engineers involved in this process.This process is developed around the TOC organization structure but it can be adapted to other industries and organizations.

RESPONSIBILITIES

The qualified engineer is responsible for the structural integrity of lifting attachments. The work tasks of the qualified engineer, except approvals, may be delegated to other qualified engineers.Responsibility cannot be delegated.

GUIDANCE

For TOC contractor, the purpose is to ensure lifting attachments are tagged and in the lifting attachment database. Lifting attachments that do not have tags need to be inspected photographed and analyzed prior to lifting; and tagged after the initial lift is complete.

For any standard of-the-shelf attachments should meet ASME B.30 standards. For Special or Critical lifts, standard of-the-shelf attachments must meet ASME B.30. For newly installed or manufactured lifting attachments (less than 12 months old) where: (1) calculations meet or exceed the analysis criteria in RPP-8360, showing adequate strength of the lifting attachmentsand/or load testing results demonstrate strength in excess of 125% of the load for each lift attachment; and (2) a QA receipt inspection has been performed, the field inspection requirements, Inspection Preparation Section, of this procedure do not apply, and the receipt inspection documentation for the system, structure, or component is substituted for a field inspection. Regardless, Field Inspection Section of this guidance shall apply, and photographs are taken and included as input to the Lifting Point Database.

Inspection Preparation

Engineer 1. Based on a scheduled need to perform a lift, have the QualifiedEngineer check the database for existing calculations and field inspections; provide supporting documentation to planner as needed.

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2. If the lifting attachment is not in the database, either fill out the Lifting Attachment Field Report by Engineer (Attachment C), photograph the specific lifting attachment, and go to Field Inspection; or have a QA inspection performed using the Lifting Attachment Field Inspection Report by QA (Attachment D).

QA inspection is required when the lifting attachment is damaged or visibly bent.

3. Review the field inspection folder for completeness and accuracy, anddeliver the package to QA with the instruction to complete the inspection.

Field Inspection

Qualified Engineer 1. Evaluate the field inspection report, and based on findings, perform the required actions to ensure that the identified lifting attachmentscan be safely used.

a. Ensure a work order for any lifting attachments requiring corrective maintenance is initiated;.

b. Indicate approval by signing the inspection report(s).

c. Have the Qualified Engineer add the field inspection report to the database.

2. If required, prepare an Engineering Change Notice (ECN) to initiate repairs or to revise drawing(s) to match the “as-found” field conditions.

Qualified Rigging Engineer

3. Evaluate corrective actions and approve ECNs.

4. When frequent lifts are taking place, it is recommended to track hoisting and rigging activities: coordinate calculations, inspection of critical and special lifts required.

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Structural Analysis

Qualified Engineer 1. Perform structural analysis and provide data to planner; engage the services of a structural engineer as necessary.

2. Check the database to determine bail capacity and cover block weight.If necessary, initiate an analysis , and provide an approved inspection report to the analyst.

Analyst 3. Perform structural evaluation of lifting attachments using this procedure.

Qualified Engineer 4. Based on the structural evaluation, determine if the lifting attachment(s) is adequate to lift the intended item (e.g., cover block, cover plate, shield plug) and verify tags are in place.

a. If adequate, notify the planner and provide the planner with a copy of the analytical calculations.

b. If inadequate, contact the Engineering Discipline Lead - Civil/ Structural, for a resolution.

Analyst 5. Record analysis as required by procedures. Provide the analysis to the Qualified Engineer to document computational calculations.

6. Record inspection report results and analysis into the database.

RECORDS

The following records are generated by the performance of this procedure:

Lifting Attachment Field Inspection Report by Engineer (Attachment C)

Lifting Attachment Field Inspection Report by QA (Attachment D)

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ATTACHMENT C

LIFTING ATTACHMENT FIELD REPORT BY ENGINEER

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Pit Identification No.: Drawing Number(s):

Work Package No.:

Lifting AttachmentLocation:

Date:

This checklist is a guide to determine the existing condition and current configuration of existing lifting attachments (e.g., shape, number, orientation) for comparison to existing design drawings. All blocks on this form shall be either completed or marked “N/A” (provide a listing of all other discrepancies and/or significant observations below).

1.0 PHOTOGRAPHS

A. Attach photographs of pit, with cover blocks, to this form.

B. Take a photograph of each lifting attachment (e.g., facing the lifting attachment opening).Take a photo that shows that the bail is not bent out of plane and/or in plane (e.g., from the side). Record lifting attachment ID on the photos and attach them to this report.

2.0 STRUCTURAL INTEGRITY

Check to ensure:

No corrosion other than superficial rust

No concrete deterioration or cracking

No apparent out of plane and/or in plane bending

Actual field condition of lift attachment, cover block, etc., matches the drawing configuration.

Comments:

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Field Inspection Performed by:

Engineer (print name)

(sign name) Date

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ATTACHMENT D

LIFTING ATTACHMENT FIELD INSPECTION REPORT BY QA

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Pit Identification No.: Drawing Number(s):

Work Package No.:

Lift Point Location: Date:

This checklist is a guide to determine the existing condition and current configuration of existing lifting attachments (e.g., shape, number, orientation) for comparison to existing design drawings. Additional inspection and/or NDE may be required, if deemed necessary by engineering. All blocks on this form shall be either completed or marked “N/A” by the Inspector (Provide a listing of all other discrepancies and/or significant observations in Section 5.0).

1.0 PHOTOGRAPHS

A. Attach photographs of pit, with cover blocks, to this form.

B. Take a photograph of each lifting attachment (e.g., facing the lifting attachment opening).If the lifting attachment is bent out of plane and/or in plane, take a photo that shows this (e.g., from the side). Record lifting attachment ID on the photos and attach them to this report.

C. If there is a tag attached to the lifting attachment showing block weight and/or key block location, photograph the tag, attach it to this report, and record the block weight in “Comments” below.

Comments:

2.0 CORROSION

A. Visually inspect and photograph the lifting point.

B. If corrosion is present, other than superficial rust, describe below.

C. Record measured dimensions of the remaining material after removal of corrosion.

(Diameter Width X Thickness)

Comments:

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Leg Height = ____ in.

3.0 CONCRETE

A. If concrete deterioration and/or large cracks (>0.013”) are present around the lifting attachment, photograph the damaged area and record concrete crack dimensions for evaluation by others.

B. Measure and record size of cracks greater than .013” in width.

C. Comments:

4.0 LIFTING POINT RADIUS/SHAPE

A. Provide the characteristics listed in the figures below: If the lifting attachmentconfiguration differs from the typical lifting attachment shown below, attach a dimensioned sketch of the lifting attachment using equivalent elevation views and details.

B. Provide a tracing of the entire lifting attachment (use 11”x 17” paper if possible).

C. If the item is a cover block: Does the number and

general location of penetrations match the cover

block drawings? YES NO

D. Attach a sketch to show the size and location of anyadded or deleted features, especially for penetrations in cover blocks.

Radius = ___

Height = ______in.

Length

= _______ in.

Lifting Bar Size:

Diameter or

Width X Thickness

Angle, if lifting point is bent out of plane

= ___________°

Side View

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E. Describe the cross-section shape of the lifting attachment material (e.g., round, square, rectangular) and note any markings or abnormalities.

F. Comments:

5.0 COMMENTS OR OTHER OBSERVATIONS (attach additional sheets as required)

6.0 MEASURING AND TEST EQUIPMENT (M&TE)

Field Inspection Performed by:

Inspector (print name)

(sign name) Date

Data Reviewed by:

Engineer (print name)

(sign name) Date

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ATTACHMENT E

STANDARD SPECIFICATIONS

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HOISTING, RIGGING, TRANSPORT, DELIVERY AND STORAGE SPECIFICATION

TABLE OF CONTENTS

1.0 PART 1- GENERAL .........................................................................................1

1.1 Section Scope.......................................................................................................1

1.2 Related Sections.................................................................................................. 1

1.3 Codes and Standards........................................................................................... 1

1.4 System Descriptions............................................................................................ 2

1.5 Submittals............................................................................................................ 2

1.6 Delivery, Storage & Handling............................................................................. 3

1.7 Quality Assurance............................................................................................... 11

1.8 Site Conditions ................................................................................................... 12

1.0 PART 1 – GENERAL

1.1 Section Scope

This specification provides the generic requirements related to hoisting, rigging, deliveryand storage for all equipment associated with TOC and related projects.

In addition to the requirements herein refer to the appropriate equipment-specific sub-sections for additional requirements.

1.2 Related Sections

(as needed or as applicable)

1.3 Codes and Standards

Work shall be performed in accordance with the referenced codes, standards, and documents for this specification.

The following documents, of the exact issue shown, form a part of the basis of design to the extent specified in the applicable sections of this document and establish the Code of Record. In the event of a conflict between documents referenced herein and the requirements of this specification, the requirements of this specification shall take precedence only when this specification’s requirements are more stringent or conservative.

If the Code date is not defined, apply the latest Code as of the date of issuance of this specification. This document list is applicable to this specification only; please refer to the equipment specifications for codes and standards that apply to the equipment being supplied.

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1.3.1 Government Documents

US Department of Energy (DOE) Procedures

– DOE/RL-92-36, 2016, Hanford Site Hoisting and Rigging Manual

1.3.2 Non-Government Documents

American Society of Mechanical Engineers (ASME)

- ASME NQA-1-2008/2009A, Quality Assurance Requirements for Nuclear Facility Applications

- ASME BTH-1, Design of Below-The-Hook Lifting Devices

- ASME B30.20, Below-The-Hook Lifting Devices

1.3.3 Non-Code of Record Documents/Related Documents/Drawings

- RPP-8360 (Current revision), Lifting Point and Lifted Item Evaluation Process

- TFC-ENG-FACSUP-C-10 (Current Revision), Control of Dome Loading and SSC Load Control

- TFC-ENG-FACSUP-C-25 (Currant Revision), Hoisting and Rigging

- TFC-ENG-STD-06 (Current revision), Design Loads for Tank Farm Facilities

1.4 System Descriptions

Refer to the appropriate equipment-specific sub-sections for equipment-specific descriptions and requirements.

1.5 Submittals

1.5.1 Submittals that are listed within this section shall be prepared and processed in accordance with requirements of the related “Submittals Section”

1.5.2 Packaging, Handling, Shipping, and Storage Plan (PSSH)

1.5.2.1 VENDOR shall submit a Packaging, Storage, Shipping, and Handling (PSSH) Plan in accordance with QA Clause B85. The PSSH plan shall include all plans, procedures, and drawings that address how items will be packaged, stored, delivered, and handled in accordance with the requirements described throughout this specification with the exception of topics already covered by the Lift and Rigging Plan described in Section 1.6.4.1. Additional requirements may be described in equipment-specific specifications.

1.5.3 Summary of Submittals

The following is a list of submittals described by this specification. Refer to equipment-specific specification documents for additional submittal details.

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Table 1.5-1 - Standard Submittals for Hoisting, Rigging, Transport, Delivery and Storage

SECTION SUBMITTAL TITLE1.5.2.1 PACKAGING, STORAGE, SHIPPING, AND HANDLING (PSSH) PLAN (INCLUDING

DRAWINGS)

1.6.3.3 CLEANING RECORDS

1.6.4.1 LIFT AND RIGGING PLAN (INCLUDING DRAWINGS)

1.6.4.6 SITE ASSEMBLY INSTRUCTIONS (INCLUDING UNPACKING AND INSTALLATION DRAWINGS)

1.6 Hoisting, Rigging, Transport, Delivery and Storage

1.6.1 General

1.6.1.1 All hoisting, rigging, transport and load handling activities shall comply with DOE-RL-92-36 “Hanford Site Hoisting and Rigging Manual”, RPP-8360 “Lifting Attachment and Lifted Item Evaluation”, and TFC-ENG-STD-06 “Design Loads for Tank Farm Facilities.”

1.6.1.2 VENDOR shall receive, clean, package, store, preserve, handle, and ship Structures, Systems and Components to protect against physical damage, or any effect that would affect quality or cause deterioration at all times while items are located on the VENDOR’s premises.

1.6.1.3 VENDOR shall follow manufacturer’s recommendations for storage and handling of all purchased items.

1.6.1.4 VENDOR shall submit a Packaging, Storage, Shipping, and Load Handling (PSSH) Plan. The PSSH plan shall include all plans, procedures, and drawings that address how items will be packaged, stored, shipped, and handled in accordance with the requirements described throughout this specification with the exception of topics covered by the Lift and Rigging Plan described in Section 1.8

1.6.2 Transportability

1.6.2.1 All components, unless specified otherwise in this section or related sections, shall be compatible with being transported by public roadway to contract specified destination unless otherwise specified or allowed by equipment specific design documents and compliant with 49 CFR 393. Items shall either be self-supporting or provided with packing and dunnage so as to ensure their stability and protection from damage. Refer to equipment-specific specifications and procurement documents for limits on weight, size, disassembly, protective capability and long term storage.

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1.6.2.2 Equipment shall be packaged, supported, and secured to the transport vehicle in a manner so it can withstand a 0.8g (forward) hard-braking stop, and rearward or lateral acceleration of 0.5g, as well as, shock and vibration loads associated with transportation. Calculations that demonstrate compliance with these requirements shall be included in the PSSH plan described in Section 1.5.2.1. Note that this is the minimum requirement; if a supplier has more stringent requirements, the supplier’s requirements shall be applied. Where equipment is braced internally, it shall be marked to identify removal.

1.6.3 Packaging

1.6.3.1 Levels of Packaging

The packaging requirements shall be based on the protection that is necessary during shipping, handling, and storage of the item.

1.6.3.2 Cleaning Plan

Prior to packaging an item, debris/contamination shall be removed using VENDOR documented and approved standard procedure, unless specified otherwise.

1.6.3.3 Packing List

A detailed packing list shall be provided with each shipment. The packing list shall identify content (every item in the shipment including quantities), package type (the container it is packaged in or on), packaging materials (including temporary supports and preservatives, if used), dimensions/weight for each package in the shipment, installation drawing number references, total number of packages in the shipment, and total weight for the shipment.

1.6.3.4 Shipment Load Protection

VENDOR shall be responsible for loading, bracing, and anchoring equipment to prevent any damage during shipment. Anchoring, bracing, and loading diagram(s) shall be submitted to BUYER in the PSSH plan and approved by the VENDOR carrier/shipper. If such supports are to be removed before placing item in service, it is to be noted on VENDOR drawings.

1.6.3.5 Protection from Shock And Vibration

Cushioning, blocking, bracing and anchoring shall be used where protection from shock and vibration is required.

1.6.3.6 Other Protection

Protect equipment and finishes against impact, abrasion, and other damage.

1.6.4 Load Handling

1.6.4.1 Hoisting and Rigging Plan

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VENDOR shall provide lift and rigging plans that describe the lift points, special lifting devices and hardware, lifting and handling instructions, lift diagrams that include estimated weight and center of gravity, and lift test plans in accordance with DOE-RL-92-36, RPP-8360, and TFC-ENG-STD-06.

1.6.4.2 Lift Point Marking

Lift points shall be clearly identified on the equipment.

1.6.4.3 Rated Temperature for Custom Lifting Devices

All custom designed Hanford Site lifting devices shall be rated for cold weather temperature of 10 degrees Fahrenheit or below.

1.6.4.4 Shipping and Handling Drawing

Prior to shipment, the VENDOR shall provide detailed handling instructions including a dimensioned drawing for each equipment/assembly indicating all dimensions and tools necessary for support, lift and shipment of the completed equipment. Tolerances for such dimensions shall be noted, either on the specific dimension or in general notes. Dimensions locating centers of gravity shall be generated by VENDOR calculation and shall be noted on the drawing, and the calculations shall be submitted with the drawings. These drawings shall be provided with the PSSH plan described in the previous section.

1.6.4.5 Unpacking and Assembly Drawing

VENDOR shall provide a dimensioned drawing that includes receiving instructions, offloading and unpacking instructions, and on-site assembly instructions (if equipment is shipped in a disassembled state). These drawings shall be provided with the PSSH plan.

1.6.4.6 Special Lifting Devices

1.6.4.7 Any special handling devices needed for assembly or installation shall be identified and supplied with the equipment. All Below-the-Hook lifting devices shall be designed in accordance with ASME BTH-1 and ASME B30.20.

1.6.1 Delivery

1.6.1.1 All equipment shall be shipped in accordance with the applicable DOT standards and in an orientation ready for lifting. Additional handling of the equipment to orientate it for lifting is not acceptable.

1.6.1.2 Transport and tie-down instructions and diagrams shall be provided.

1.6.1.3 Calculations will be required for the design of all transport tie-down attachment points. Lift points shall not be used for transport tie-downs.

1.6.1.4 Transport tie-down points shall be identified on the equipment.

1.6.2 Marking For Shipment

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1.6.2.1 Prior to shipment, all packages shall be clearly and suitably tagged to identify, at a minimum:

– BUYERS name with destination address

– VENDOR’s name with return address

– Package numbers showing the Purchase Order (PO) Number followed by the package number and the total number of packages

– Package contents description

– Weight of package

– Center of gravity

– Parts list (for each package)

– Handling instructions (e.g., Fragile, Center of Gravity, Keep Dry, This Side Up, Sling Here, Do Not Freeze) and stacking limitations, as appropriate

– Special instructions (Desiccant Inside, Special Inspection, Storage, Unpacking Restrictions, etc.) as appropriate

1.6.2.2 Temporary supports shall be marked (tagged or painted).

1.7 Quality Assurance

1.7.1 Refer to equipment specific design documents for additional requirements related to quality. Applicable QA Clauses are summarized in the table below.

Table 1-2. AVS Procurement Quality Clause

MATERIAL HANDLING

B85 Packaging/Shipping Procedures

1.8 HOISTING, RIGGING, TRANSPORT AND LOAD HANDLING

1.8.1 Hoisting and Rigging Plan

VENDOR shall provide a Hoisting and Rigging Plan to cover the lifting and handlinginstructions for each lifted item (entire package as well as individual items that are un-crated). The plan shall describe the lift points, special lifting devices and/or hardwareneeds, and lift diagrams. Lift diagrams shall be dimensioned drawings for eachequipment/assembly indicating all dimensions and tools necessary for support, lift andshipment of the lifted item. Tolerances for such dimensions shall be noted, either on thespecific dimension or in general notes.

Weight of the item, as well as dimensions locating centers of gravity shall be generated by VENDOR calculation per RPP-8360 and shall be noted on the drawing, and thecalculations shall be submitted with the drawings demonstrating that the requirements ofthis section have been satisfied. These drawings shall be provided with the PSSH plan.

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1.8.2 Lifting Attachments and Equipment Design

The VENDOR may use these specifications for design, or provide lifting instructions proprietary to the manufacturer. Lift instructions shall provide the same information required above including lifting attachment locations and how to lift the item. Calculations on the lifting attachments may be required for custom made equipment and must be provided for Special or Critical lifts.

The requirement of NQA-1 2008 and addendum 2009 shall be applied to all hoisting and rigging equipment and related procurements. The Rigging Engineer will use a graded approach in the selection of rigging hardware. At a minimum, Quality Level 3 (QL-3) must be used for all hoisting and rigging procurements. BTH lifters, rigging equipment, slings, hardware, etc. used for critical lifts may need to be procured to QL-2 or possibly QL-1.

The objective of the process is to ensure that all items to be lifted and their lifting attachments, can withstand the loads imposed by lifting operations with acceptable margins of safety. Equipment designs, tests, and reports shall be submitted for evaluation and approval during design review. Design shall include load conditions for lifting the load and rotation of the load from horizontal to vertical if appropriate. The suspended assembly shall hang true vertical end to end. This process shall also ensure the design includes the ability to safely remove the item from a facility at the end of its design life. Long length equipment must provide an area free of sharp edges or corners at the lower end of the equipment such that a choke hitch using a synthetic sling may be used during equipment removal.

The lifting attachment(s) on the equipment (lifting eyes, lugs, ears, etc.) and the lifted item shall be designed in accordance with the following procedure except ASME BTH-1 Design of Below-the-Hook Lifting Devices (BTH-1) should be used to verify lifting lugs hole diameter compared to the shackle pin diameter (the D to d ratio). The analysis shall follow TFC-ENG-DESIGN-C-10 Attachment A – Calculation Format and Preparation Instructions and the analysis method described in RPP-8360

1.8.3 Lift Point Marking

Lift points for packages and individual components shall be clearly identified.

1.8.4 Critical Welds

• All critical welds shall be identified in the VENDOR’s design media.• For the purpose of this requirement, critical welds are defined as those welds

whose failure could result in loss of load or loss of load control.• All critical welds on lifting devices shall be full-penetration welds, if possible.• Critical welds shall be verified by Non-Destructive Examination.

1.8.5 Special Lifting Devices

Any special handling devices needed for assembly or installation shall be identified andsupplied with the equipment. VENDOR provided structural and mechanical liftingdevices, as defined by ASME B30.20 Below-the-Hook Lifting Devices, shall conform tothe requirements of ASME B30.20 and ASME BTH-1 Design of Below-The-Hook LiftingDevices. BTH devices shall be load tested in accordance with ASME B30.20. All

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custom designed lifting devices for use on the Hanford Site shall be rated for cold weather temperature of at least 10 degrees Fahrenheit.

1.8.6 Below-the-Hook Device Markings

BTH lifting devices shall be provided with markings in accordance with ASME B30.20 and tags in accordance with DOE-RL-92-36. In addition to the requirements of ASME B30.20 and DOE-RL-92-36, the marking shall include Hanford drawing number (if applicable), special lifting instructions, and clearly indicate lifting attachments. The marking shall be in the form of a name tag, name plate, or other permanent marker.

1.8.7 Pump Handling

Lifting instructions and lift diagrams shall be provided. The lift diagram must show estimated weight and center of gravity. The lifted item must be level and plumb when suspended. The design shall consider the pump assembly orientation, i.e., horizontal to vertical. All lift points, both permanent and temporary, shall be identified on the pump assembly.

The VENDOR shall provide a lift analysis to ensure the fully assembled pump assembly and cover plate (as applicable) can be lifted without distortion, damage, or exceeding allowable stresses. A temporary attachment point on the pump column at a location analyzed to prevent pump damage shall be clearly identified.

The VENDOR shall provide the 2 permanent lifting attachments near the top of the EAPS, and shall detail any special handling requirements in the instruction manual to ensure that the pump assembly can be safely lifted and installed without damage to the pump or tank. All drawings and procedures required for pump installation/removal and operation shall be included in the manual for quick reference.

During the removal of long length equipment from waste tanks, the contaminated equipment is routinely wrapped in plastic making it difficult to determine the lower lift point location. A choke hitch using a polyester sling is normally used at the lower end of the equipment. It is important to provide a safety location, an area free of sharp edges or corners that could cut the sling, for the choke hitch attachment. An area free of sharp edges or corners, on the lower end of the equipment, shall be provided for attachment of a choke hitch during equipment removal.

The pump assembly shall be stored and transported utilizing a strong back to prevent damage while in the horizontal orientation. The Seller shall design and provide a strong back to allow the pump assembly to be repositioned, loaded, and off-loaded from a truck trailer via three methods:

A single crane utilizing a spreader bar with rigging attached to designated strong back lift points.

Two cranes utilizing a designated lift point on each end of the strong back.

Two forklifts utilizing designated engagement sleeves along the strong back.

The design shall also include supports for long-term warehouse storage of the pump assembly in a horizontal orientation. This design shall provide adequate support along the entire length of the EAPS and allow for mobilization of the EAPS within the warehouse.

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