RIGGING PROGRAM REQUIREMENTS

Safety Training: Technical Training

TSP 18.721

SAFETY FIRST

This course is best viewed with headphones or speakers; the audio portion enhances the presentation.

Rigging Program Requirements00059223


Increase the participant’s knowledge of the information and requirements inside the TVA Safety Procedure (TSP) “Rigging” and the TVA “Rigging Manual”.

Upon completion of this course, you will demonstrate your knowledge of TVA’s Rigging Program Requirements according to TVA Safety procedure TSP 18.721, as presented in the course material. Successful completion requires a minimum score of 80% on a written examination.

Terminal Objective


1. Understand the correct definitions of rigging terms used in TSP 18.721 and TSP 18.721A.

2. State the individual roles and responsibilities required of persons involved in rigging and rigging support activities at TVA sites.

3. Identify the three rigging classifications and state the criteria used for these classifications.

4. Identify the type of rigging planning that is required, the criteria for planning, and who is responsible for planning and approval.

5. State the required controls for working near or in the load drop zone (LDZ) and other safety requirements at TVA sites.

Enabling Objectives


Understand the Correct Definition of Rigging Terms used in TSP 18.721 and TSP 18.721A.

Objective 1


Process of lifting that would elevate a freely suspended load to such a position that dropping the load would possibly cause bodily injury or property damage.

Overhead Lifting


A system comprised of all load bearing components used to lift the load, including the crane or hoist, the lifting device, and the interfacing load lift points.

Overhead Handling System


A lift that is performed multiple times, using the same hook and rigging. This type of lift may involve different personnel during its execution.

Redundant Lift

The significance of this type of lift is discussed later in the presentation.


A lift that is performed multiple times, using the same hook and rigging. This type of lift must use the same personnel throughout its execution.

Repetitive Lift

The significance of this type of lift is discussed later in the presentation.


Used either singularly or in combination to attach a load to a lifting device for the purpose of stabilizing, lifting, pulling, or

moving a suspended load.

Rigging


A hoist placed between the load and the hook of the overhead handling equipment or in series with a sling used to lift a load.

Intermediate Hoist

Example: Chain-falls, come-a-longs, turnbuckles, etc. used as load leveling devices.


Any hardware used to suspend an object from a crane or hoist hook.

Lifting Device


A term used to identify the maximum load the rigging configuration can support.This capacity is dependent upon:

• Rigging hardware size• Its associated working load limit (WLL)• The angle in which the load is applied• The number of lifting/load attachment points incorporated

Rigging Limited Capacity as Configured


Any fabricated assembly designed to attach a load to a hoist mechanism that is used to transport the load by suspending or lowering.

Below the Hook (BTH) Lifting Device


Specific, identified normal lifts performed in TVA NPG that must follow a standardized rigging plan using dedicated rigging hardware and lifting devices at each execution of the lift.

Table 34Pre-Approved Rigging for Lifts Using Polyester Round Slings

Pre-ApprovedSling Color

Vertical RatedCapacity

Maximum AllowableLifted Load

Green 5,300 lbs. 4,000 lbs.

Tan 10,600 lbs. 8,000 lbs.

Blue 21,200 lbs. 16,000 lbs.

Brown 52,900 lbs. 40,000 lbs.

Table 34 is not to be used for lifts requiring COMPLEX rigging.

Instructions and detailed rigging plans are located in TSP 18.721A under Appendix A “ Pre Approved Lifts”.

Pre – Approved Lifts (NPG only)


Rigging that has been checked out of the tool room or designated storage area (i.e. attached to a load, hook, lifting device, or staged in a work area).

Any rigging found unused must be inspected then returned to the tool room or designated storage area.

Any rigging suspected to be contaminated must be placed in the proper location for decontamination.

All rigging undergoing decontamination shall be considered out of service until released by RADCON.

In-Use Rigging (NPG only)


State the individual roles and responsibilities required of persons involved in rigging and rigging support activities at TVA sites.

Objective 2


Ensures lifting and rigging conforms to the TVA Rigging Procedures.

Helps in the development of training and qualification of all riggers.

Helps develop rigging plans.

Provides oversight to ensure inspection, inventory, and issuance of rigging equipment are performed in accordance with TSP 18.721 “Rigging.”

Rigging Program Coordinator


Ensures riggers are qualified and proficient.

Ensures vendors and supplemental workers are qualified.

Ensures personnel under their supervision perform rigging according to procedure.

Supervisor/Foreman


Qualified rigger

Responsible for safe conduct of rigging portion of lift

Determines load path & lay-down area prior to lift

Ensures personnel are not positioned between load and objects

Person in Charge (PIC)

The Person In Charge also maintains control of the Load Drop Zone,

absolutely no one can enter the load drop zone without permission from the

Person In Charge.

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Develops normal rigging plans

Obtains weights and centers of gravity

Understands limitations of rigging

Understands requirements for lifting

Complies with plant/site load path requirements

Inspects rigging

Uses only approved rigging

Maintains good housekeeping of rigging

Basic Rigger


Performs all basic rigger responsibilities

Develops and approves complex rigging plans

Oversees selected lifts to determine if adequate skills, equipment, and practices are in place

Provides feedback or concerns regarding the rigging program, rigging skills, or training needs to the Site Rigging Program Manager

Advanced Rigger


Shall be a qualified rigger Be involved in and know the rigging plan Discusses with the crane operator any blind or inaccessible areas and how

flagging will be performed Be aware of the environment and surroundings, rigging hardware, lifting

equipment, and devices During lifting operations, the signal person shall remain attentive to the task Shall be in constant communication (radio or visible) with the operator at all

times Only responsibilities shall be to flag, monitor, and position the load Required for lifts requiring a crane operator and use of signal method A designated signal person is optional for lifts using pendant cranes, radio

control cranes, chain falls, come-a-longs, winch, hoist, forklift attachment, or block and tackle where verbal communication (radio or telephone is not considered verbal) is used to transmit hoisting instructions.

Signal Person


EXCEPTIONS: For certain types of rigging activities, such as those involving pendant or radio

controlled shop cranes, it may be acceptable for a person to perform more than one assignment.

If due to limited personnel at a given worksite there is only one qualified rigger, the PIC may also act as the signal person provided the following conditions are met:

1. While acting as a signal person, the only responsibility carried out will be to flag, monitor, and position the load.

2. Responsibilities of the PIC while acting as the signal person are carried out by other personnel so designated by the PIC. The personnel so designated must be given specific instructions on their responsibilities and the manner in which they are to be carried out.

For these situations, the rigging program coordinator may evaluate and approve them on a case-by-case basis using TVA Form 20403, TVA Rigging Plan and/or TSP Plan Jobs Safely.

Signal Person


Approves rigging used for temporary structural supports using an engineer with experience and qualifications necessary to perform calculations and determine structural adequacy.

Provides input/approval on rigging plans when requested.

Provides approval of Temporary Rigging Load Permits as submitted (NPG Only).

Rigging used for temporary structural support (wire rope lashing, come-a-longs, chain-falls, or other means) remain in place until item is secured in its permanent location.

Engineering

All rigging used for temporary structural support shall be inspected prior to performing any work on the equipment that it supports.


Trained and qualified to inspect rigging

Issues rigging only to qualified riggers

Ensures no defective rigging is issued

Removes, tags, and segregates all defective rigging

Required to complete the same training as a basic rigger

Tool Room/Rigging Storage Attendants (as Applicable)


General Responsibilities (Management Expectations for all Lifts)

TVA qualified rigger will direct each rigging activity.

Everyone involved will attend a pre-job briefing.

Only rigging with current annual inspection will be used.

Qualified rigger will inspect all rigging prior to and after each lift.

Inspect, as necessary, during use.

The annual inspection is identified by a color code system and is discussed in detail in the TVA instructor led course on Rigging Fundamentals.


Use only established and approved rigging practices found in TSP 18.721A.

Use only rigging purchased in accordance with ASME B30 standards or fabricated under TVA approved specifications.

Do not alter unless approved by Engineering.


Safety Manual

TSP 18.721A

RiggingManual


Determine accurate load weight prior to lift.

Verify weight with load cell, if necessary.

Load must be free prior to being rigged for a lift or use load moment indicator, load cell, etc., so as not to exceed safe work load of the crane, hoist, or rigging.

Protect slings from sharp edges of their loads.

Use the “Two Minute Rule” process by completing the Rigging Card prior to making the lift.

The rigging card is not a substitute for the Two Minute Rule card, the two minute rule is completed upon

arrival at the job site.



Qualified Riggers

Maintain good housekeeping of all rigging after obtaining it and prior to its return

Inspect rigging prior to, during, and after use

Return to proper storage when job is complete

Defective rigging shall be tagged using form TVA 18004 “Defective Equipment Tag” and removed from service and, as appropriate, repaired or destroyed.



Identify the three rigging classifications and state the criteria used for these classifications.

Objective 3


Lift Must Include All Attributes

Known center of gravity (CG)

Load attachment points above the CG

Sling angle is 45o or greater from the horizontal

Single hook from overhead handling equipment

Drift angle equal to or less than 15°

Load weight is 39,999 pounds or less

Formal lift plan is not required unless engineering assistance is requested

Normal Rigging

NORMAL

Lift plans for normal rigging can be initiated and approved by a basic rigger


Lift Must Meet One or More Factors

Unknown CG or CG is 12” or more off the geometric center in any direction

Load attachment points below the CG

Sling angle less than 45° above the horizontal

More than one hook from overhead handling the equipment

Drift angle greater than 15°

Load weight equal to or greater than 40,000 pounds

Requires a formal lift plan (TVA form 20403) that must be approved by an Advanced Rigger or designated qualified person

Complex Rigging

COMPLEX


Established by Nuclear Regulatory Committee in 1980 applicable to all Nuclear generating stations in the United States

Intended to lessen the possibility of lift failures in Critical Lift Zones (CLZ) of nuclear generating stations

Defines weight as more than the combined weight of a single fuel assembly and its associated handling tool

Dedicated lifting devices designed specifically for handling a certain load or loads

Procedures are specific to generating station Browns Ferry 1,000 pounds Watts Barr 2,059 pounds Sequoyah 2,100 pounds

NUREG-0612 Heavy Load Rigging (NPG Only)


Identify the type of rigging planning that is required, the criteria for planning, and who is responsible for planning and approval.

Objective 4


All lifts require some form of planning.

No documentation is required for normal rigging, except when Engineering assists with the planning.

Pre-job brief discussion:1. PIC2. Signal person3. Load drop zone4. Any other factors impacting the

activity

TVA rigging card is required to be completed for all lifts and is completed after all rigging is installed and the load is attached to hook.

Normal Rigging


Complex rigging

Any lift requiring Engineering assistance

Any other lift where a written lift plan has been deemed necessary

Exception: If the lift is covered by a site procedure, a vendor drawing, engineering design output, or by the TVA Rigging Manual, Form TVA 20403 is not required.

TVA 20403 Rigging Plan Use Requirements

TVA 20403


Section 1.0 Station and exact location where

lift is to be performed Task or Work Order Number UNID or physical description of

object being lifted Load weight and how weight was

determined Exact location where lift will be

conducted Rigging classification and reason

for the classification Intermediate hoist or special

hitch configuration

TVA 20403 Rigging Plan Required Information


DoubleInvertedBasket

SingleInvertedBasket

DoubleChokerEyes Up

TwoSingle

Baskets

Use of any of these hitches or any hitch not shown in Table A-33 OF TSP 18.721A

TVA 20403 Rigging Plan Use Required for these Hitches

These hitches have been identified as having poor load control


Section 2.0 Description of rigging

configuration and all equipment that will be used

Sketch may be used instead of description

Limited capacity of rigging as configured must be determined

Has engineering assistance been requested

Type of engineering assistance and requestor

TVA 20403 Rigging Plan Required Information


Normal Rigging Lifts• Initiation – Basic Rigger• Approval – Basic Rigger

Complex Rigging Lifts• Initiation – Basic or Advanced

Rigger• Approval – Advanced Rigger or

designated qualified person

TVA 20403 Rigging Plan Completion and Approval


Section 3.0 and 4.0

Signatures of preparer and approver

Dates of initiation and approval

Approver’s position

Signature of PIC

Suggested processing of lift plan

TVA 20403 Rigging Plan Required Information TVA 20403 Rigging Plan Required Information


Required any time rigging is attached to a plant civil feature or any feature not designated for rigging purposes

Handrails, instrument lines, or small piping, are never to be used as rigging attachment points

Requires signature verification of BOTH a qualified rigger and foreman

Foreman must verify rigging has been installed per section 1.4 of permit, or any engineering provisions established

A copy of the approved permit must be posted at the jobsite

TVA 20404 Temporary Rigging Load Permit (NPG only)


Required for every rigging job

Enforces STOP, THINK, ACT, and REVIEW before performing lift

No substitute for Form TVA 20403 (Rigging Plan)

Maintained at lift location during lift

Completed in the field, after rigging installation, and prior to making lift

PIC signs prior to making lift

Any block marked “no” requires Concurrence

TVA Rigging Card Use


Used for redundant lifts if attributes re-verified by PIC

If used for redundant lifts, must use reverse side of card

If attributes change, a new card is required

Repetitive lifts by the same crew may use the same card without re-verification

Electronic versions or duplicates permitted

TVA Rigging Card Use (cont.)


State the required controls for working near or in the load drop zone (LDZ) and other safety requirements at TVA sites.

Objective 5


An area in which an injury may occur if a load falls.

LDZ Area, unless defined in the Job Safety Analysis, procedure, or boundary controls equals:• Height of object + Distance raised, up

to maximum of 10 feet• Continuously around object

For objects greater than 10 feet, the Radius of 10 feet + Height of the object.

D

D

H

D+H D+HLoad Drop Zone

Load Drop Zone

Lifts Less than 10 Feet Above the Floor

Lifts Greater than 10 Feet Above the Floor

10’or Greater

D+10’ D+10’

D = Vertical Distance of the Object

Load Drop Zone (LDZ) Area

Note: These are the absolute MINIMUM requirements for a load drop zone


Personnel remain outside the LDZ Permission to enter is required from PIC Prior to lift, verify that:

• Load path is clear of obstruction and other activities

• Continuous, unobstructed ingress and egress path is established

• Controls for monitoring boundary of zone are established

• No one is allowed under the load

Passing a load over personnel or equipment requires “High Hazard Lift” planning

LDZ Requirements

When placing barricade tape to mark the boundaries of a load drop zone, red and black “DANGER” tape shall be used


1. Rigging Plan

2. Specific assignments

3. Communication methods

4. LDZ size and control

5. Safe egress

6. Load control

7. Load positioning

8. Emergency stop signal

9. Location of power disconnects

10. Contingencies

Pre-Job Briefings (PJB)

In addition to the required PJB items in the Plan Jobs Safely procedure, when lifting and rigging activities are planned, the following items need to be addressed:


Preferred Method of Load Control

Discuss in PJB

Long enough to clear LDZ

Never wrap around a body part

Attach as far away from center of gravity as possible

Trail the load

Use Shepherd’s Hook or similar device to reach tag line or to adjust cribbing

Load Control with Tag Line

Tag lines should also be long enough, or personnel positioned such, that the line is at an angle no more than 45° from horizontal


Tag lines have been identified as ineffective for the application

Bottom of load is no more than chest high above landing area

No risk of being struck by the load if it swings or falls out of control

Hazards identified and precautions taken to prevent tripping and falling under load

Hand and body part hazards for pinch points are evaluated and eliminated or controlled

Employee Guiding a Suspending Load

The pre-job briefing will identify the need for being in the LDZ to guide the load.

Employees can get near a load and assist in guiding the load into place with their hands, provided ALL of the following requirements are met:


Rigging used for support during pre-positioning of machines, piping, platforms, walkways, and steel members, is not to be removed until all leveling and alignments are complete and the item is secured in place.

Inspect rigging after use

Clean work area

Return rigging to storage

What Do I Do When the Rigging Job is Complete?


Any time rigging and lifting of a load is performed, there is the potential for an accident.

Loads can and do fall.

Rigging accidents are never planned, they occur when things are overlooked or safety rules are violated.

No one wants a rigging accident to happen, nor do they want to be involved in one.

This course has been developed to inform you of the TVA Rigging Program requirements in an effort to prevent rigging accidents from occurring.

Always use safety first as a rule, when performing rigging activities.

Summary


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RIGGING PROGRAM REQUIREMENTS