[Hallb-engineering] Fwd: Lesson Learned "Nylon Sling Fails during Lift due to Sharp Edges on Material Being Lifted - Frontier North, Inc."

Douglas Tilles tilles at jlab.org
Mon Nov 3 12:37:32 EST 2014

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From: mbailey at jlab.org
To: mbailey at jlab.org
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Sent: Monday, November 3, 2014 12:00:30 PM
Subject: Lesson Learned "Nylon Sling Fails during Lift due to Sharp Edges on Material Being Lifted - Frontier North, Inc."

	Nylon Sling Fails during Lift due to Sharp Edges on Material Being Lifted - Frontier North, Inc. 	
Statement of Lessons Learned 
For a copy of the original report, see �Attachments� on Lessons Learned page. 

Failure to use break point softeners on a load with sharp edges and failure to perform inspection of slings between lifts resulted in sling failure and a drop of one side of the load. Discussion of Activities 
On August 2, 2014, stacks of cell hatch covers were being relocation in an effort to create space for ongoing deactivation activities.  Each stack consisted of eight covers having a combined weight of approximately 3200 lbs.  The crew had lowered seven stacks without incident.  When the eighth stack had been rigged, lifted, and moved to the lowering location the signal person notified the crane operator to hold the load until a fork truck passed through the area. While the load was being held in a standby position, one of the two nylon slings broke, dropping one end of the load approximately 6-inches. Analysis 
Inspection of the sling at the break point showed signs of a sudden tear.  Inspection of the load showed that the hatch covers sharp sheet metal edges came in contact with the sling, tearing it under load; causing the sling to break.  Although involved personnel were qualified as riggers and trained to use break point softeners when there was potential for sling damage, interviews with the crew revealed that softeners were not used.  Also, the lift checklist did not prompt the Qualified Rigger to determine and document whether softeners were even considered. 

This same lift using the correct rigging and softeners had been performed hundreds of times over the last two years without any report of sling damage.  An extent of condition was performed which involved the inspection of slings used by other crews who perform the same evolution.  No evidence of damage was noted on the other sling with softeners. Recommended Actions 
Below are the consequences of the above event.  They are provided for information and discussion purposes only. 

�	Personnel involved in the lift were disqualified as qualified riggers and the supervisor was removed from supervising hoisting and rigging activities until after completion of remedial training.
�	Appropriate disciplinary actions were taken.
�	The use of nylon slings for this evolution was temporarily suspended pending appropriate compensatory measures.
�	A standing order was issued providing directions to reinforce the use of softeners when the potential for sling damage exists.
�	Shift briefs were conducted with personnel prior to using nylon slings for hatch cover lifting.
�	Site hoisting and rigging technical procedure and lift check sheet were revised to create a documented decision point to determine if softeners are required. JLab Preventive Measures 
Jefferson Lab only allows individuals who are trained and qualified access to overhead cranes/hoists.

In accordance with ES&H Manual Chapter 6141 Appendix T3 Inspection Procedures � slings are to be inspected prior to each use.

In accordance with ES&H Manual Chapter 6141 Appencis T4 Hoisting and Rigging Operations (Including Planning a Lift) � a pre-engineered production lift requires an Operational Safety Procedure to be reviewed by Subject Matter Experts and those performing the work prior to commencement of operations. 
11/3/2014 11:53:14 AM by Bailey, Mary Jo 
Submitted to those with current training:
�SAF403: Overhead Crane Operator Qualification 	
Summary 	Lesson ID: 	858 
	Status: 	OK 
	Doc ID: 	2014-JLAB-858 
	Priority: 	Info 
	Safety Related: 	YES 
	Originator: 	Bailey, Mary Jo 
	Issued: 	11/3/2014 11:51:21 AM 
	Approved By: 	Bailey, Mary Jo 
	Approved On: 	11/3/2014 11:53:14 AM 
	Source: 	DOECRD 
	Location: 	OTHER 
	Cost Savings: 	
	Contact: 	Dwayne McCloskey, Facility Stabilization and Deactivation Process Equipment, 740-897-3856 
	Queued Emails: 	0 
	Sent Emails: 	0 
	Viewings: 	1 times Attachments 

Hazard Issues 

    * Material Handling Equipment 
    * Cranes & Hoists 
    * Lifting/Moving Objects 

    * SAF403: Overhead Crane Operator Qualification 

    * *Division Safety Officers (DSOs) 
    * *Safety Wardens 
    * *DOE Notification 
    * *ESH&Q Liaisons 

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