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NOAO Doc #: 2100-AD-015-0102 DESI Doc #: DESI-4578-v2 Revision: B
Spectrograph Lift: Removal of Inner Crate from Outer Crate at the Mayall
Author(s): Andrew Lambert, Patrick Jelinsky
2100-AD-015-0102 Page 2 of 18
Contents
Revision History3
1.0 Purpose4
2.0 Applicable To4
3.0 Scope4
4.0 Definitions4
5.0 Training4
6.0 Safety4
7.0 Personnel, Equipment and Material Required5
8.0 Procedure6
9.0 Procedure Review13
10.0 Records13
11.0 References13
2100-AD-015-0102 Page 3 of 18
Revision History
REV
Date Approved
Sections
Affected
Reason for Change
Remarks and/or Change Details
Name
- 01-29-2019 All Initial Release d.spray
A 03-06-2019 All EC 201903-0086 d.stover
B 04-07-2020 All Finalized and reviewed m. evatt
Approved by:
Matt Evatt
Name, ME Manager
Bob Stupak
Name, EL Maint
SigSci
Name, SciOps
Tammie Lavoie 07 April 2020
Tammie Lavoie, Safety Manager Date
2100-AD-015-0102 Page 4 of 18
1.0 Purpose This document describes the procedure to lift the DESI spectrograph and Inner Crate out of the Outer Crate and position the Inner Crate for unpacking and eventual Spectrograph transport to the M-floor.+
2.0 Applicability and Starting Conditions
Applies to DESI Spectrograph forklifting for removal of the Spectrograph + Inner Crate from the Outer Crate on the Mayall ground floor:
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
Outer Crate at the Mayall 2.1.2 Front and top covers of Outer Crate removed, with crossbar, brackets and ratchet
straps removed, front cover should face the Mayall garage door (See DESI-3801 for unpackaging instructions).
2.2 State of the Linde H40T forklift: 2.2.1 Forklift shall be fully prepped for the move at the Mayall
3.0 Scope and Analyses
This document covers all the steps required to lift the DESI Spectrograph, while inside the Inner Crate, from the Outer Crate for eventual transport to the Mayall M-floor
4.0 Definitions
4.1 Outer Crate: Outer shipping crate for the DESI Spectrograph, houses the Inner Crate; this is re-used so please take care when handling it. 4.2 Inner Crate: Inner shipping crate for the DESI Spectrograph; this is re-used so please take care when handling it. 4.3 Winlight: Manufacturer of the DESI Spectrograph
5.0 Training
5.1 Forklift operator training and current certification for operator of H40T forklift
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 Critical Lift Plan Form
6.2 Daily Briefing Form
6.3 JHA Form(s)
6.4 NOAO-N Stop Work Policy, NOAO Doc# 1000-AD-015-0012
6.5 KPNO Emergency Manual, NOAO Doc# 1000-AD-015-0034
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6.6 Personal Protective Equipment Policy, NOAO Doc# 1000-AD-015-0008
6.7 Slips, Trips & Falls Policy, NOAO Doc# 1000-AD-015-0014
6.8 Ergonomic Awareness Policy, NOAO Doc# 1000-AD-015-0022
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 Linde H40T Forklift 1 Must have current training certification
Overhead Crane Operator 1 Must have current training certification
Lead Rigger 1 Must have current training certification
Signal Person 1 Must have signal training
Lookouts/Guides 2 May NOT be same person as operator
Safety Watch 1 May NOT be any of the above personnel
2100-AD-015-0102 Page 6 of 18
Table 2: Required Equipment
Equipment #/Items Referred To As
Linde H40T Forklift 1 “H40T Fork”
4400lb capacity pallet jack 1 “pallet jack”
4-leg bridle, 10 ft per leg, 10,200 lbs per leg
1 “4-leg bridle”
3-ton overhead crane 1 “3 ton crane”
8.0 Procedure
This procedure starts with the DESI Spectrograph inside its Outer Crate with the crate fully closed
Table 3: Weight Summary for Items being lifted
Description Approx. Size Weight
DESI Spectrograph with Inner Crate
- Full assembly minus the cryostats
2053mm x 1536mm x
821mm
10124 N
[2276 lbf]
Task Leader to initial each step as it is completed.
7.1 ____Unpack Outer Crate per the Winlight Procedure, as documented in the Appendix of this document, also refer to DESI-3801 7.1.1 Remove cover using 3-ton crane and 4-leg bridle 7.1.2 Remove front panel by hand 7.1.3 Remove lateral beam (no screws, lifts out) 7.1.4 Remove ratchet strap 7.1.5 Remove metal brackets 7.2 ____Verify the DESI Outer Crate has had its front and top removed, along with any insulating foam that may be in the way. Note: Please take care with Outer Crate materials as this crate must be sent back to Winlight to be re-used for future Spectrograph shipments, see Figure 1.
2100-AD-015-0102 Page 7 of 18
Figure 1: DESI Spectrograph Crate with top and front panels removed, insulation removed
7.3 ____DESI Outer Crate is positioned on the Mayall garage floor as shown in Figure 2
Figure 2: Initial Position of DESI Spectrograph Crate
8.0 ____Deploy personnel as follows: 8.1.1 Forklift driver to Linde H40T
2100-AD-015-0102 Page 8 of 18
8.1.2 One signal person, with two lookouts (lookout may be signal person) 8.1.3 Safety watch to monitor space and personnel
9.0 Drive forklift up to crate and position forks under inner crate as seen in Figure 3.
Figure 3: Forklift under Inner Crate
9.1.1 Note: The Inner Crate is slightly recessed inside the Outer Crate, which will
not allow the load to be fully positioned against the backstop of the forklift. This requires an initial re-positioning using the forklift where the Inner Crate is lifted slightly to allow shifting across the base of the Outer Crate until there is enough clearance for the forks to fully engage under the load, see Figure 4
2100-AD-015-0102 Page 9 of 18
Figure 4: Inner Crate re-positioning for lift
10.0 Insert forks under the Inner Crate as far as they can reach 11.0 Bring forks up on slowest setting until Inner Crate load is just released from the base of
the Outer Crate 12.0 Backup forklift 3”-4” or until the front edge of the Inner Crate first meets the foam
insulation on the base 12.1.1 Note: Station lookouts on both sides to watch for clearance and damage to
Outer Crate
2100-AD-015-0102 Page 10 of 18
JHA: CB – Keep hands and fingers clear of sides while moving crate. Make sure to be wearing appropriate gloves while working with the wooden crate.
13.0 Lower Inner Crate back down until it is fully supported on the Outer Crate base, drive forklift the rest of the way in until the Inner Crate wall meets the forklift backstop. Note: the forks are 72” and the Inner Crate is 70” deep, so the forks will protrude beyond the backside of it by ~2”. Spotters are necessary to watch so as the forks don’t damage the outer crate.
14.0 Gently lift the Inner Crate and pull it clear of the Outer Crate 15.0 Pause and check the forklift and load, back Inner Crate away from Outer Crate as
shown in Figure 5 JHA: SL – Suspended load, use caution around forklift. Make sure area is clear of people and objects that could be in the way.
Figure 5: Linde H40T lifts Inner Crate and backs up away from the truck
16.0 Backup the forklift straight back from the crate, completely out of the garage 16.1 ____Move Outer Crate with pallet jack as far as possible into the clean tent
2100-AD-015-0102 Page 11 of 18
Figure 6: Move Outer Crate into tent using pallet jack
16.2 ____Bring forklift back into garage and drive Inner Crate to target zone, under the hatch opening.
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Figure 7: Drive Inner Crate to target zone under Dome hatch
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Figure 8: DESI Spectrograph under the dome hatch
17.0 Slowly lower Inner Crate for soft landing centered under the dome hatch, back forklift away, do not raise forks or turn until clear of crate
JHA: CO, SA – Be aware of surroundings as you back away from the load.
18.0 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.
19.0 Records
19.1 JHA Signature Sheet 19.2 Personnel training records 19.3 Rigging 19.4 Critical Lift
20.0 References
DOCUMENT
NUMBER
DOCUMENT TITLE
DESI-3801 WS2711-003-PRO-004-B: “Unpacking, Packing and Inspection Procedure of DESI Spectrograph”
DESI-4578 Removal of Inner Crate from Outer Crate at the Mayall CLP
2100-AD-015-0102 Page 14 of 18
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-015-0102 Page 15 of 18
Appendix:
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