NOAO Doc #: 2100-AD-015-0100 DESI Doc #: DESI-4503_v4 Revision: -

Spectrograph Lift: Ground Floor to Main Floor

Author(s):, Andrew Lambert, Patrick Jelinsky, David Sprayberry

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Contents

Revision History3

1.0 Purpose4

2.0 Applicable To4

3.0 Scope5

4.0 Definitions5

5.0 Training5

6.0 Safety5

7.0 Personnel, Equipment and Material Required6

8.0 Procedure7

9.0 Procedure Review14

10.0 Records14

11.0 References14

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Revision History

REV

Date Approved

Sections

Affected

Reason for Change

Remarks and/or Change Details

Name

- 04-07-2020 All Initial Release Evatt

Approved by:

SigEng

Name, ME Title

SigEM

Name, EL Maint

SigSci

Name, SciOps

Signature 20 March 2019

Tammie Lavoie, Safety Manager Date

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1.0 Purpose This document describes the procedure to lift the DESI spectrograph from the ground floor to the main floor at the Mayall Telescope, as seen in Figure 1.

Figure 1: DESI Spectrograph Lift

2.0 Applicability and Starting Conditions

Applies to DESI spectrograph installation, movement of the spectrograph from ground floor to main floor Coude Room for eventual installation on rack

2.1 State of the DESI Spectrograph prior to start: 2.1.1 DESI Spectrograph shall be packaged and protected inside its inner crate and

positioned on the ground floor next to the landing area centered under the hatch from the main floor

2.1.2 DESI Spectrograph shall be unboxed following the procedure outlined in Section 11.0 of this document, and center under the hatch

2.2 State of the 4-pt lifting beam prior to start: 2.2.1 4-pt lifting beam shall be stored on a cart positioned near the hatch on the

main floor 2.3 State of the rigging components prior to start

2.3.1 All rigging shall be stored on the ground floor, except for the 7/8” Shackle and master link which shall be stored with the 4-pt lifting beam on the main floor

2.4 State of the dome prior to start

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2.4.1 Main floor hatch center section open (could have entire hatch open but only center section needed)

3.0 Scope and Analyses

This document covers all the steps required to lift the DESI Spectrograph from the ground floor of the Mayall building to the Main floor

4.0 Definitions

4.1 Inner Crate: Inner shipping crate for the DESI Spectrograph; this is re-used so please take care when handling it. 4.2 4-pt beam: Custom 4-point lifting fixture developed by Winlight; analyzed and load tested 4.3 Handling Cart: Cart on the M-floor used for moving DESI Spectrograph into the Coude Room 4.4 Winlight: Manufacturer of the DESI Spectrograph

5.0 Training

5.1 Crane operator training and current certification for operator of the 5-ton dome bridge crane. 5.2 Rigger/signaler training for the lead rigger(s) and all required signalers.

6.0 Safety

Job Hazard Analysis (JHA) and remediation actions are included in the procedure in “red”. See Legend below for “Hazards Present” Acronyms. JHA sign off sheet is located at end of the document.

6.1 Crane Certifications

6.2 Cranes Standard Operating Policy NOAO Doc# 1000-AD-015-0010

6.3 Critical Lift Plan Form

6.4 Daily Briefing Form

6.5 JHA Form(s)

6.7 NOAO-N Stop Work Policy, NOAO Doc# 1000-AD-015-0012

6.12 KPNO Emergency Manual, NOAO Doc# 1000-AD-015-0034

6.13 Personal Protective Equipment Policy, NOAO Doc# 1000-AD-015-0008

6.14 Slips, Trips & Falls Policy, NOAO Doc# 1000-AD-015-0014

6.15 Ergonomic Awareness Policy, NOAO Doc# 1000-AD-015-0022

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Acronyms for “Hazards Present”

AX – Asphyxiation HS – Heat stress

BR – Burn Hazard R – Repetitive Motion

CB – Caught Between SA – Struck Against

CBY – Contacted By SB – Struck By

CI – Caught In SE – Stored Energy

CO – Caught On SL – Suspended Load

CW – Contact With TH – Trip Hazard

E – Exposure to Chemicals, Noise, Vibration, Radiation

EL – Electrical

ER – Ergonomics

FB – Fall to Below

FH – Fire Hazard

7.0 Personnel, Equipment and Material Required

Table 1: # of Personnel

Role #/Personnel Notes

Operator for 5-ton Overhead Dome Crane 1 Must have current training certification

Lead Rigger 1 Must have current training certification

Signaler 2 Must have current training certification; one may be same person as lead rigger

Lookouts/Guides 4 May NOT be same person as signaler

Safety Watch 1 May NOT be any of the above personnel

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Table 2: Equipment

Equipment #/Items Referred To As

WS2711-942-F010: Custom 4-pt lifting beam designed by Winlight

1 “4-pt lifting beam”

Alloy Screw Pin Shackle, 3/8”, 2T WLL, AK60002

8 “2 ton shackle”

Alloy Screw Pin Shackle, 1-3/8”, 18T WLL, AK60008

1 “18 ton shackle”

Crosby 84,900lb master link, see DESI-4120 for details

1 “Master link”

Nylon Wear-Resistant Eyeless Web Slings, 1” wide x 3’ long, 6200 lb WLL

4 “Web slings”

DESI Spectrograph Handling Cart 1 “Handling cart”

4400 lb capacity Pallet Jack 1 “Pallet Jack”

8.0 Procedure

This procedure starts with the DESI Spectrograph inside its Inner Crate, fully enclosed.

Table 3: Weight summary for items being lifted

Description Approx. Size Weight

DESI Spectrograph

Full assembly minus the cryostats and spectrograph controller, but with 8020 framing on outside

2053mm x 1536mm x

821mm

6695.3 N

[1504.6 lbf]

4 point lifting beam 1700mm x

1310mm x

250mm

1471.5 N

[330.7 lbf]

Task Leader to initial each step as it is completed.

7.1 Verify the DESI Spectrograph and 4-pt lifting beam pre-assembly are in place 7.1.1 4-pt beam, master link and 1-3/8” shackle positioned on M-floor, on rolling

cart. 4’ webbing slings should be attached to the corners of the 4-pt beam, with the 2-ton shackles installed on the slings.

7.1.2 DESI Spectrograph, enclosed in its inner crate. 7.1.2.1 Note: Base of the Inner Crate is still present 7.1.2.2 Pallet jack on hand for moving the DESI Inner Crate if need be

8.0 Deploy personnel as follows: 8.1.1 Crane operator to dome crane operator’s station

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8.1.2 Primary signal person to ground floor garage 8.1.3 Lead rigger to M-floor 8.1.4 ____Lookouts/guides to ground floor garage 8.1.5 Secondary signal person to the main floor by crane hatch 8.1.6 Safety watch to the ground floor garage

8.1.6.1 Note: Observe protocols for signaling and handoff of control for multi-floor lifts as described in Cranes SOP, 1000-AD-015-0010.

9.0 Rotate the dome and move the dome crane trolley to position the 5Ton crane hook over the 4-pt lifting beam, the 4-pt beam can be seen in Figure 2

JHA: SL – All personnel should have hard hats on while crane is in motion.

Figure 2: 4-pt lifting beam for DESI Spectrograph

10.0 Begin lowering the 5Ton dome crane hook towards the M floor. 11.0 Position and lower hook until it is within reach of M16 hoist ring located on the center-

top of the 4-pt lifting beam; move the rolling cart as needed to center the 4-pt lifting beam directly under the hook

12.0 Lead rigger secure the hook to the 4-pt lifting beam M16 hoist ring using the 18 ton shackle and Master link

13.0 Once secure raise the 4-pt lifting beam off its cart and rotate dome such that 4-pt beam is South of dead center of the hatch

JHA: CB, CO SL – Watch for pinch points as you start to raise the lifting beam. With a suspended load people should not be working underneath load.

14.0 ____ While Steps 9.0 – 13.0 are underway, the personnel on the ground floor should be unboxing the DESI Spectrograph inner crate per the procedure outlined in WS2711-003-PRO-004-B (DESI-3801), starting in Section 6.0 on page 10.

14.1.1 Note: do not proceed on to Step 15.0 until the ground floor unboxing work is complete.

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15.0 Begin lowering the 4-pt beam to the ground floor, passing through the hatch on the second floor, lead rigger to go down to ground floor at this point

16.0 Lower the hook until the M16 hoist rings on the underside of the 4-pt lifting beam are near eye-level to personnel on the ground floor

17.0 Rig a 2 ton shackle to each of the M16 hoist rings on the underside of the lifting beam and rig a web sling in vertical configuration to each of the four shackles

JHA: CB - Watch for pinch points. 18.0 Lift 4-pt beam such that the bottom of the web slings are approximately 5 feet off the

ground, “trolley out” to go North and put lifting beam above spectrograph

Figure 3: DESI Spectrograph, ready for lifting

19.0 Lower lifting beam, with guides at all four corners, until bottom of web slings are approximately 2 ft off the ground

JHA: SA – Make sure when lowering that 4pt beam does not strike spectrograph, radio communication from primary signaler to crane operator is required. Keep slings from striking the spectrograph.

20.0 ____Plastic zip ties are used to mark the orientation of the 4pt lifting beam to the Spectrograph. Align the zip ties on the lifting beam M16 hoist ring to the zip ties on the spectrograph M12 hoist ring, as shown in Figure 4

Note: Proper alignment places the lifting fixture central pick point above the Spectrograph CG. Do not proceed until lifting beam alignment is verified and lifting beam is properly centered over the Spectrograph.

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Figure 4: 4pt Beam Alignment

21.0 Rig web slings to M12 hoist rings on the DESI Spectrograph using the 2 ton shackles 22.0 ____ Slowly raise the hook until web slings begin to become taut, but not fully loaded

JHA: CB-watch for pinch points 23.0 Using a 13mm socket wrench with ratchet handle, remove the 16 screws that attach the

DESI Spectrograph to the wire rope isolators, as instructed on page 12 of “WS2711-003-PRO-004-B: “Unpacking, Packing and Inspection Procedure of DESI Spectrograph” (DESI-3801). Save the bolts for later reinstallation.

24.0 Pause, check rigging, and adjust as needed. Lower hook slightly if necessary to adjust. The assembly should appear as it does in Figure 5

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Figure 5: Rigged DESI Spectrograph for lift from Ground floor to M-floor

25.0 Slowly raise the crane hook until the load is floating and continue raising slowly until the DESI Spectrograph is well clear of the Inner Crate base

26.0 Leave Inner Crate in place in case the process must be reversed 27.0 When the DESI Spectrograph remains stable and is not swinging, lift the crane hook at

normal speed (starting slowly, and increasing speed incrementally) until the DESI Spectrograph has passed safely through the main floor hatch.

JHA: SL – Suspended load, make sure no personnel under load, signaler must maintain view of load JHA: CO – Make sure load cannot be caught on anything while being raised. Be aware of surroundings. 27.1.1 Observe the SOP protocols below for hand-off of control from the primary

signaler on the ground floor, to the secondary signaler on the main floor. 28.0 Once the DESI Spectrograph has cleared the 3rd floor all ground-floor personnel

EXCEPT the primary signaler should immediately return to the M floor, by the Coude’ Room. 29.0 After the DESI Spectrograph is safely clear of the main floor hatch and handrails,

continue raising and begin rotating the dome so as to position the DESI Spectrograph over the cart near the Coude’ Room entrance on the M floor, see ..Figure 6

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..Figure 6: Spectrograph set-down lobbcation

30.0 Under the direction of the secondary signaler, orient the cart at 90 degees (horizontally) to the spectrograph bench. Lower the spectrograph until the bottom of the optical bench is making contact with the cart slings still have some tension.

31.0 ____ Cut off the bottom corners of the protective bag surrounding the spectrograph. Attach the rubber feet to the underside of the bench by screwing them in firmly by hand.

31.1.1 Note: the rubber feet should be contained in the small crate containing the spectrograph controller which was delivered with the spectrograph.

31.2 ____ Under direction of the secondary signaler, lift the spectrograph about 6 inches clear of the cart.

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31.3 ____ Rotate the cart underneath the spectrograph to align the corners of the cart underneath the corners of the spectrograph. 31.4 ____ Under direction of secondary signaler, lower the DESI Spectrograph until the bottom surfaces of the landing pads are 2” off the cart landing surface, re-position the cart as necessary, see Figure 7. JHA: SL – Suspended load, make sure no personnel under load, signaler must maintain view of load 31.4.1 NOTE: lookouts/guides may need to gently touch the base of the

spectrograph to eliminate swinging while lowering.

Figure 7: DESI Spectrograph handling cart

32.0 Under the direction of the secondary signaler, lower the Spectrograph while guides/lookouts check cart alignment and adjust as needed. Prior to set-down lock cart wheels.

JHA- CO, SA – Be aware of people and objects in the area. 33.0 Begin slowly lowering the dome crane hook at speed 1 so that the DESI Spectrograph

makes a soft landing on the cart. 34.0 Once the Spectrograph is fully settled on the cart, lower the crane hook until there is

enough slack in the web slings to remove the shackles rigging the slings to the M12 hoist rings

34.1.1 Note: Do not leave the removed shackles on the slings, but store them in a safe place that is out of the way, preferably on a rolling cart

34.2 Raise the hook such that the slings cannot catch on the Spectrograph, then move the Spectrograph into the Coude’ Room for storage using the handling cart 34.3 Lower the hook and remove the remaining rigging and store with the 4-pt beam on the rolling cart

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35.0 Procedure Review

This procedure must be reviewed if changes are made to the DESI Spectrograph or the 4-point lifting beam that might affect this procedure.

36.0 Records

36.1 JHA Signature Sheet 36.2 Personnel training records 36.3 Rigging 36.4 Critical Lift

37.0 References

DOCUMENT

NUMBER

DOCUMENT TITLE

DESI-1885 WS2711-001-RAP008-A: Winlight Calculation Report “DESI – Bench Assembly – Lifting mechanical results”

DESI-3278 WS-PVC2944-A: Winlight Inspection Report “Optical Bench deformation inspection after lifting”

DESI-3802 WS2711-001-NDC001-E: Winlight Calculation Report “Lifting tool for the DESI Spectrograph”

DESI-3803 WS-PVC3054-A: Winlight Inspection Report “Lifting tool inspection”

DESI-3803 WS2711-942-COC001-A: Winlight Certificate of Compliance “DESI Spectrograph Lifting tools SN001 and SN002”

DESI-3801 WS2711-003-PRO-004-B: “Unpacking, Packing and Inspection Procedure of DESI Spectrograph”

DESI-4503 Spectrograph Ground Floor to Main Floor Critical Lift Plan

DESI-4556 FEA of DESI Spectrograph Handling Cart

JHA SIGN Off Sheet:

WORK GROUP MEMBERS FOR THIS JHA

I understand & will adhere to the steps, hazards & controls as described in this JHA. I understand that performing steps out of sequence may pose hazards that have not been evaluated, nor authorized. I will contact my supervisor prior to continuing work, if the scope of work changes or new hazards are introduced. I understand I have the authority and responsibility to stop work if I believe it to be unsafe.

N° NAME (print) SIGNATURE DATE

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SUPERVISOR IN CHARGE

I have reviewed the steps, hazards & controls described in this JHA with all workers listed above and authorize them to perform the work. Workers are qualified (i.e. licensed or certified, as appropriate, & in full compliance with NOAO training requirement(s) to perform this activity.

N° NAME SIGNATURE DATE

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