NOAO Doc #: 2100-AD-015-0100 DESI Doc #: DESI-4503_v3 Revision: - Spectrograph Lift: Ground Floor to Main Floor Author(s):, David Sprayberry, Matthew Evatt, Tammie Lavoie, Don Friend, Gaston Gutierrez, Giuseppe Gallo
Contents Revision History... 3 1.0 Purpose... 4 2.0 Applicable To... 4 3.0 Scope... 5 4.0 Definitions... 5 5.0 Training... 5 6.0 Safety... 5 7.0 Personnel, Equipment and Material Required... 6 8.0 Procedure... 7 9.0 Procedure Review... 13 10.0 Records... 13 11.0 References... 14 2100-AD-015-0100.Docx Page 2 of 16
Revision History REV Date Approved Sections Affected Reason for Change Remarks and/or Change Details Name - 12-21-18 All Initial Revision Lambert Approved by: Matt Evatt Name, ME Title John Donaldson Name, EL Maint David Sprayberry Name, SciOps Tammie Lavoie 21 December 2018 Tammie Lavoie, Safety Manager Date 2100-AD-015-0100.Docx Page 3 of 16
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 2.4.1 Main floor hatch center section open (could have entire hatch open but only center section needed) 2100-AD-015-0100.Docx Page 4 of 16
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 2100-AD-015-0100.Docx Page 5 of 16
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 Lead Rigger 1 Signaler 2 Lookouts/Guides 4 Safety Watch 1 Must have current training certification Must have current training certification Must have current training certification; one may be same person as lead rigger May NOT be same person as signaler May NOT be any of the above personnel 2100-AD-015-0100.Docx Page 6 of 16
Table 2: Equipment Equipment #/Items Referred To As WS2711-942-F010: Custom 4-pt lifting beam designed by Winlight 1 4-pt lifting beam Actek 60002 Alloy Screw Pin Shackle, 3/8, 2T WLL, AK60002 8 2 ton shackle Actek 60016 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 4 point lifting beam 1700mm x 1310mm x 250mm 6695.3 N [1504.6 lbf] 1471.5 N [330.7 lbf] Task Leader to initial each step as it is completed. 8.1 Verify the DESI Spectrograph and 4-pt lifting beam pre-assembly are in place 8.1.1 4-pt beam, master link and 1-3/8 shackle positioned on M-floor, on rolling cart 8.1.2 DESI Spectrograph, Unbox DESI Spectrograph inner crate per the procedure outlined in WS2711-003-PRO-004-B, starting in Section 6.0 on page 10, also found at DESI-3801 8.1.2.1 Note: Base of the Inner Crate is still present 8.1.2.2 Pallet jack on hand for moving the DESI Inner Crate if need be 8.2 Deploy personnel as follows: 8.2.1 Crane operator to dome crane operator s station 2100-AD-015-0100.Docx Page 7 of 16
8.2.2 Primary signal person to ground floor garage 8.2.3 Lead rigger to M-floor 8.2.4 Lookouts/guides to ground floor garage 8.2.5 Secondary signal person to the main floor by crane hatch 8.2.6 Safety watch to the ground floor garage 8.2.6.1 Note: Observe protocols for signaling and handoff of control for multifloor lifts as described in Cranes SOP, 1000-AD-015-0010. 8.3 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 8.4 Begin lowering the 5Ton dome crane hook towards the M floor. 8.5 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 8.6 Lead rigger secure the hook to the 4-pt lifting beam M16 hoist ring using the 18 ton shackle and Master link 8.7 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. 8.8 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 8.9 Lower the hook until the M16 hoist rings on the underside of the 4-pt lifting bean are near eye-level to personnel on the ground floor 2100-AD-015-0100.Docx Page 8 of 16
8.10 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. 8.11 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 8.12 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. 8.13 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. 2100-AD-015-0100.Docx Page 9 of 16
Figure 4: 4pt Beam Alignment 8.14 Rig web slings to M12 hoist rings on the DESI Spectrograph using the 2 ton shackles 8.15 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) 8.16 Slowly raise the hook until web slings begin to become taut, but not fully loaded JHA: CB-watch for pinch points 8.17 Pause, check rigging, and adjust as needed. Lower hook slightly if necessary to adjust. The assembly should appear as it does in Figure 5 2100-AD-015-0100.Docx Page 10 of 16
Figure 5: Rigged DESI Spectrograph for lift from Ground floor to M-floor 8.18 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 8.19 Leave Inner Crate in place in case the process must be reversed 8.20 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. 8.20.1 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. 8.21 Once the DESI Spectrograph has cleared the 3 rd floor all ground-floor personnel EXCEPT the primary signaler should immediately return to the M floor, by the Coude Room. 8.22 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 2100-AD-015-0100.Docx Page 11 of 16
Figure 6: Spectrograph set-down location 8.23 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 8.23.1 NOTE: lookouts/guides may need to gently touch the base of the spectrograph to eliminate swinging while lowering. 2100-AD-015-0100.Docx Page 12 of 16
Figure 7: DESI Spectrograph handling cart 8.24 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. 8.25 Begin slowly lowering the dome crane hook at speed 1 so that the DESI Spectrograph makes a soft landing on the cart. 8.26 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 8.26.1 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 8.27 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 8.28 Lower the hook and remove the remaining rigging and store with the 4-pt beam on the rolling cart 9.0 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. 10.0 Records 10.1 JHA Signature Sheet 10.2 Personnel training records 10.3 Rigging 10.4 Critical Lift 2100-AD-015-0100.Docx Page 13 of 16
11.0 References DOCUMENT NUMBER DESI-1885 DESI-3278 DESI-3802 DESI-3803 DESI-3803 DESI-3801 DESI-4503 DESI-4556 DOCUMENT TITLE WS2711-001-RAP008-A: Winlight Calculation Report DESI Bench Assembly Lifting mechanical results WS-PVC2944-A: Winlight Inspection Report Optical Bench deformation inspection after lifting WS2711-001-NDC001-E: Winlight Calculation Report Lifting tool for the DESI Spectrograph WS-PVC3054-A: Winlight Inspection Report Lifting tool inspection WS2711-942-COC001-A: Winlight Certificate of Compliance DESI Spectrograph Lifting tools SN001 and SN002 WS2711-003-PRO-004-B: Unpacking, Packing and Inspection Procedure of DESI Spectrograph Spectrograph Ground Floor to Main Floor Critical Lift Plan FEA of DESI Spectrograph Handling Cart 2100-AD-015-0098 Spectrograph Lift: Ground Floor To Main FloorHA Appendix 1. Fermilab Engineering Note MD-ENG-569 DESI Barrel HMP Three Lifting Hoist Rings Analysis 2100-AD-015-0100.Docx Page 14 of 16
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 1 2 3 4 5 6 7 8 9 10 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 1 2100-AD-015-0100.Docx Page 15 of 16