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LIFT TRUCK OPERATIONS PROCEDURE

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DOCUI\fENT TITLE:
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LIFT TRUCK OPERATIONS PROCEDURE
'PJ(, ~')t (# 27
003 Issued for Usc
I sue: for Use 04-rcb-2019 . . . ._rn l-J r.,~ h1t JD
Issued for DOC.
002
Approvll
13-Jan-2019 JIB NM ER JD DOC. SIZ E: A4 PAGE 1 OF 14
IPA(,EtOr2 REV.
CATEGORY: R
Issued for COMPANY J B
001 18-0ct-2018 J-ffi Nlv( f!R JD DOC. NO.:
Review NO. BOC 1561
M GP 1-CP2-PI L-HS-6180-0015 003
REV. DESCRWfiON DATE PRPD CIIKD APPD AI' PO JOI3. NO.: JI-2042
 DOCUMENT TITLE: Rev. 003
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MGP1-CP2-PIL-HS-6180-0015 Page 2 of 14

HOLD LIST

Hold
Para. Description of Hold
No.
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TABLE OF CONTENTS

1 INTRODUCTION ................................................................................................................ 4

2 PURPOSE ..............................................................................................................................4

3 SCOPE .................................................................................................................................... 4

4 DEFINITION AND ABBREVIATIONS ............................................................................. 5

5 REFERENCE ........................................................................................................................6

6 ROLES AND RESPONSIBILITIES.....................................................................................6

7 INCIDENT REPORTING ................................................................................................... 7

8 PROCEDURE VIOLATION ................................................................................................ 8

9 SAFETY REQUIREMENTS FOR LIFT TRUCKS .............................................................8

Minimum Safety Requirements .......................................................................................................... 8

Lift Truck Fuelling And Battery Charging ....................................................................................... 8
Pre-Work Inspection of Lift Trucks.................................................................................................. 8
10 LIFT TRUCK OPERATING PROCEDURE ....................................................................... 9

General requirements .......................................................................................................................... 9

Load shifting ......................................................................................................................................... 9
Safe load moving requirements .......................................................................................................... 9
Approach to the load .........................................................................................................................10
Lift truck parking:...............................................................................................................................10
Lift truck outriggers ...........................................................................................................................10
Lift truck travelling.............................................................................................................................10
Lift truck travelling in proximity to excavations ............................................................................10
Lift truck repairs .................................................................................................................................11
PPE requirements ..............................................................................................................................11
Lift truck documentation ..................................................................................................................11
Annual lift truck inspection requirements ......................................................................................11
11 TRAINING REQUIREMENTS. ........................................................................................ 12

12 ADMINISTRATION OF SAFETY PROCEDURE ........................................................... 12

Safety Procedure Owner ...................................................................................................................12

Revision Cycle.....................................................................................................................................12
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1 INTRODUCTION

The aim of this Forklift Operations Procedure is to communicate the requirements to be adhered while
performing work with lift trucks.

The Procedure has been written to provide those personnel, who is required to work with, and in close
proximity to, lift trucks with useable guidelines to reduce the risk working with this type of equipment to
ALARP. Information from this Procedure shall be cascaded to Project personnel through training
sessions, toolbox talks and Ad Hoc Safety stand downs to assure their understanding of these
requirements.

Control is verified through inspections, reviews and audits. Where inadequacies are identified the relevant
activity will be suspended and corrective measures implemented.

Operating lift trucks is not classified as a Project Golden Rule of Safety but incidents can lead to serious
injuries and or damage to equipment and property. With the aim of “Goal Zero” i.e. no harm to people
and no significant HSSE incidents causing harm a Zero Tolerance approach shall be taken in the case of
contravention of this Procedure. The seriousness of this will be emphasised during the HSSE induction
processes and various other HSSE training sessions which shall be conducted during the execution phase
of the Project.

As per the Contract No. BOC-1561 Section IIIB – General Terms and Conditions, Clause 9.6(a)(i),
Contractor will pursue the HSSE principle of “Goal Zero” during the execution of the Project. Contractor
will comply with the HSSE & SP requirements of the Contract and Company’s Life Saving Rules not only
as a contractual obligation but also with a genuine intent to create a culture that ensures “Goal Zero” (no
harm to people, property and the environment). Specifically, Contractor will comply with all relevant
Company HSES-SP Policies, Standards and Procedures for the duration of the Contract as detailed in
Section VIII, Section VIII (A) Part A, Section VIII (A) Part (C), and Section VIII Part (B) of the Contract.

2 PURPOSE

The purpose of this Forklift Operations Procedure is to provide the necessary information to fully
understand the hazards associated with the operation of forklifts and to ensure that risks are reduced to
ALARP.

In addition, this Procedure provides all levels and management and workforce with:
 The knowledge required to identify safe and unsafe situations where persons are working near forklifts
 Knowledge of the methods to limit man machine interface

3 SCOPE

This Procedure covers all forklift operations performed by Contractor and its subcontractors within the
Majnoon CPF2 Project Area and PIL Area of Responsibility.
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4 DEFINITION AND ABBREVIATIONS

a. Definitions
Barricade An obstruction, such as tape, rope, netting, flasher units or traffic cones, placed in
such a way as to prohibit personnel and/or equipment from passing into an area where
hazards may be present. A barricade must present an easily recognizable warning
against entry.
Note: Colored warning tape, rope, cones or flasher units alone do not serve as a physical barrier and
should only be used as a temporary measure until permanent barriers are provided. An exception can be
made for no or low traffic areas.
Competent A person who has the knowledge and experience and is able to perform the specific
Person work requirements of this Procedure and relevant regulatory requirements.
Supervisor A trained and competent person who is assigned responsibility to:
 Verify work site activities are in compliance with approved Project Procedures
and good safety practice.
 Ensure competence of the workers and operators under his control – trained and
certified.
 Ensure only certified operators operate forklifts / equipment.
 Stop work activities when unsafe actions/conditions are identified.
 Ensure equipment under his control is maintained in accordance with
manufacturers’.
Note: All the lift trucks listed below in this Safety Procedure will be hereinafter referred to as “Lift truck
Forklift Also called forklift truck, fork truck. A small vehicle with two power-operated prongs
at the front that can be slid under heavy loads and then raised - for moving and loading
materials.
Pallet jack A pallet jack, also known as a pallet truck, is a tool used to lift and move pallets.
Pallet jacks are the most basic form of a forklift and are intended to move heavy or
light pallets within a warehouse;
Telescopic Telehandlers are utility lifting machines, usually mounted on a four-wheel drive
Handler chassis and equipped with a telescopic boom that can provide lift heights to 15m or
more. Telehandlers most often are fitted with pallet forks for lifting materials over
longer distances or greater heights.
A term which combines the chance that a specified undesired event will occur and the
severity of the consequences of the event.
Risk The product of the measure of the likelihood of occurrence of an undesired event and
the potential adverse consequences which this event may have on people, assets,
environment, and company reputation.
Service providers, consultants, licensors, and all other parties engaged to perform a
Sub-contractor
service.

b. Abbreviations
HSSE-SP Health, Safety, Security, Environment, and Social Performance
HSSE-MS Health, Safety, Security, and Environment Management System
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MFD Majnoon Field Development

PIL Petrofac International Limited
PPE Personal Protective Equipment

5 REFERENCE

Title Document Number

Company Standards and Procedures)

Majnoon HSSE & SP Commitment & Policy
Majnoon Integrated HSSE & SP Management System VEN-00000-00-SIPD-HX-5880-00001
MFD Procedure: HSSE&SP and LSR Violation
Consequence Management
Procedure: Incident Reporting and Follow-Up
Project Plans and Procedures
Emergency Response Plan
Incident Reporting and Investigation Procedure
Hazard Analysis and JSA Procedure
Training Management Plan
Contract HSSE Management Plan
GEN-00000-SIPD-00-HX-6180-00030
VEN-00000-SIPD-00-HX-6180-00007
VEN-00000-SIPD-00-HX-6180-00001
MGP1-CP2-PIL-HX-2318-0001
MGP1-CP2-PIL-HS-6180-0023
MGP1-CP2-PIL-HS-6180-0025
MGP1-CP2-PIL-HS-5798-0004
MGP1-CP2-PIL-HX-5798-0001

6 ROLES AND RESPONSIBILITIES

Roles Responsibilities
PIL Site Manager  Ensure that all lift truck operators have are qualified / certified to operate lift truck
type for which they have been appointed.
 Ensure that all contractor lift trucks pass Project annual inspection conducted by
a Qualified Crane, Rigging and Lifting Inspector from a MFD approved 3rd Party
Company.
 On a regular basis check the current list of the inspected lift trucks to ensure that
PIL and the subcontractors who own lift trucks, have addressed all non-
compliances identified during the annual inspection and have applied proper color
coding for the current year.
Lift Truck Owner  PIL or Subcontractor takes responsibility for organizing and conducting monthly,
quarterly and annual technical inspection and safe operation of lift trucks.
Maintenance Lead  Ensures lift truck maintenance is performed as per schedule.
/ Supervisor  Ensures preventative maintenance is performed to meet the requirements of the
manufacturer and this procedure; and eliminate defects, if any appears.
 Provide appropriate monthly, quarterly and annual inspections.
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 Ensures load tests are carried out when required.

 Keep original certification, operation and maintenance documentation for each lift
truck.
 Has oversight over subcontractors’ management of their lift trucks in accordance
with this procedure.
 Take responsibility for any use of an unserviceable lift truck.
Crane, Rigging  Conduct annual inspection and certification of PIL and contractor lift trucks.
and Lifting  Inspect forks, outriggers and detent pins for wear-out, cracks or deformation signs.
Inspector  Conduct additional checkups in accordance with the Project procedures.
Lift Truck  Know the limits and operating characteristics of the lift truck.
Operator  Accepts responsibility for use of any unserviceable lift truck.
 Know and verify the weight of the load with the documentation provided by his
supervisor prior to making the lift.
 Exercise Stop-Work-Authority whenever he/she believes the loading/unloading
operations may be unsafe. Refuse to continue loading/unloading until the concern
has been reported to his supervisor and safe conditions have been established.
 Perform daily and periodic check of a lift truck as per this procedure.
 Check the site conditions (such as poor visibility, equipment in close proximity,
and soil conditions, etc.) that could affect the lift truck operation; perform the
work accordingly.
 Shut down and secure the lift truck systems and mechanisms properly when
leaving the cabin.
 Keep track of the frequency of maintenance and service performed on lift trucks.
Signalman  Wear a high visibility vest (e.g., orange, yellow) to identify himself to the lift truck
operator and other traffic participants.
 Be present at all times when the lift truck is loading/unloading and pay particularly
close attention to work whenever:
o The lift truck is backing up or making any other maneuver, and where the
operator cannot see the path of travel.
 Be positioned in full view of the lift truck operator; or be close enough when using
hand signals, so the signals can be clearly seen.
 Keep unauthorized personnel, not involved in the loading/unloading process,
outside of the operating lift truck area by ensuring barricades are in place.

Note: Signalmen are not required when a lift truck is operating in open areas – only
required in congested areas. This will be evaluated on site to ensure the safety of the
signalman as well as other workers in the area.

7 INCIDENT REPORTING

Any incident involving a lift truck will be investigated in accordance with the approved PIL Incident
Reporting and Investigation Procedure (MGP1-CP2-PIL-HS-6180-0023).
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8 PROCEDURE VIOLATION

Any violation of this procedure will be investigated in accordance with the PIL HSSE Deviations
Management Plan and corrective actions implemented accordingly.

9 SAFETY REQUIREMENTS FOR LIFT TRUCKS

Minimum Safety Requirements

 Documentation certifying completion of all inspections, tests and technical maintenance service
shall be provided for each lift truck.
 All protrusive parts of a lift truck that can pose a hazard during operation of the unit, shall be coated
with yellow warning paint.
 A lift truck shall be equipped with sound and light alarms to ensure safety of operations: sound
signal (Horn), backing signal, headlamps (single/multiple), turn indicators and parking lights.
 A lift truck shall have a relief valve in the hydraulic system preventing the mechanism from lugging.
Both the valve and the device shall activate when the rated load capacity being 1.2-1.4 of the nominal
capacity, is exceeded.
 Changes or modifications to the original design of the lift truck which may affect its hoisting capacity
or safe operation are prohibited; unless it is approved and documented by the manufacturer.

Lift Truck Fuelling and Battery Charging

 Prior to fueling, the lift truck shall be properly parked, with the hand brake on and engine off.
 Refueling shall only be done in a designated refueling area which is compliant to Project
requirements.
 A fire extinguisher shall be made available at the fuel servicing place and a fuel tanker shall be
grounded.
 The battery charging area shall be open or ventilated on a permanent basis.
 Portable eye wash station shall be installed in the charging area.
 Charging clips should be attached to the battery according to the polarity.

Pre-Work Inspection of Lift Trucks

 Prior to operating a lift truck, a pre-work inspection of the technical condition shall be performed
by the lift truck operator using an approved inspection checklist in accordance with the type of
equipment being used i.e. Forklift, Tele-Handler and Pallet Jack. The completed checklist shall be
kept in the lift truck cabin for the entire shift.
 Operating a lift truck is prohibited if the inspection per the checklist identifies any operational faults.
 All faults found shall be recorded in the inspection checklist and the information communicated to
the Supervisor.
 The Supervisor shall take immediate action to correct the identified faults.
 If faults cannot be immediately rectified the lift truck will be parked with a “Do not use” sign.
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10 LIFT TRUCK OPERATING PROCEDURE

General requirements

 Prior to work, a Job Hazard Analysis (JSA) shall be performed or a Standard Operating Procedure
form completed to identify all hazards associated with the task and hazard mitigation measures and
controls.
 All lift truck devices and attachments shall be utilized in accordance with the intended design
purposes, and within the safe working limits as specified by the manufacturer and by this document.
 Personnel are prohibited from standing on the load being moved. It is prohibited to use lift trucks
to lift people as any abrupt movement/stop may cause the person standing on the platform to fall.
 Personnel are prohibited to stand on forks while the lift truck is moving.
 No passengers are allowed on the lift truck at any time i.e. sitting next to the Operator.
 Work shall be suspended if changes are introduced to the area conditions or work steps specified in
the initial plan.
 Do not exceed the maximum rated capacity of the lift truck. The rated load capacity shall be visible
– written on a manufacturer plate and one attached to the lift carriage.

Load shifting

 Loads shall be safely secured, avoiding overbalance of the lift truck. Do not move any damaged load
without having fixed it first.
 The load shall be lifted / lowered in a vertical position by the lift carriage.
 When moving the load, the lift carriage shall be inclined backward, to decrease the distance of the
load from the tips of the forks.
 Do not move the load with the carriage inclined in the forward direction.
 When moving loads which cannot be balanced due to its center of gravity the heaviest part of the
load shall be distributed closer to the lift truck front wheels. It is recommended to use alternative
ways to move it, such as cranes if the heaviest part of the load cannot be distributed.
 When moving with/without a load, the forks shall be positioned in a transporting position, i.e. lifted
200-300mm above the ground, with the back incline employed.
 Chemical agents shall be moved as per the recommendations in the Material Safety Data Sheet
(MSDS).

Safe load moving requirements

 The load shall be positioned on the forks so to prevent overturning and, at the same time, pressed
against the forklift frame.
 Prior to lifting, the operator shall check the load weight per the load documentation, and define the
load type by the signs/ labels (glass, fragile items, etc.).
 Do not push the load off a stack, or pull it closer to the stack.
 Long and/or oversized loads shall not be moved over long distances. Such loads shall be transported
by a lift truck only in open areas with even surfaces.

Important: When defining a way of transporting oversized and/or long loads, use a crane and trucks as
the preferred option.
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Approach to the load

 Drive up to the load slowly; maintaining 2km/h speed or less.

 Ensure the load is located in front of the forklift and the forks are positioned at the required width
based on the load size.
 Prior to moving the load, stop the forklift at 20-30 centimeter distance from the load to be moved
and align the forks at the load level prior to further insertion into the apertures.
 Do not elevate/lower the forks until the load rests against the frame of the forklift.

Lift truck parking:

Prior to leaving the forklift cabin the operator shall:

 Lower the forks onto the ground;
 Set on parking brake;
 Switch off the engine;
 Remove the ignition key.

Lift truck outriggers

 Lift trucks equipped with outriggers shall be positioned with the outriggers set up on an even,
compacted, intact surface.
 Pads shall always be used under the outriggers to distribute the load and the weight of the lift truck
evenly on the ground.
 During the lift all outriggers of the lift truck must be in completely extended position and laden.

Note: Pads can be made of steel or wood; steel pads provide more rigidity.

Lift truck travelling

 Lift trucks shall travel using designated routes as indicated during the work planning stage by the
Supervisor.
 When starting to move forward/back, approaching an operational area, a sound signal shall be given.
 For travelling across the area the speed limit shall not exceed 5km/hr. When travelling around
building corners, or over intersections, the speed shall not exceed 3 km/hr.
 A signalman shall be utilized when travelling between buildings or congested areas – to be evaluated
/ identified on site.

Lift trucks travelling indoors: entry/exit to/from the premises is only allowed when the gates are fully
open; the lift truck operator shall observe the speed limit of 5km/hour when indoors, and shall give a
sound signal when travelling across low visibility areas. A signalman shall be utilized at the entry / exit
points of buildings to ensure the travel route is clear for safe travel.

Lift truck travelling in proximity to excavations

When travelling in proximity to trenches or excavations, lift trucks shall maintain the minimum distances
requirements as per the table below.
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Table 1: Minimum Distance from Lift Truck to Excavation

Minimum distance
Depth of
(meters) from the lift
excavation
truck supports to the
(meters)
excavation edge
1 1.5
2 3.0
3 4.0
4 4.0
5 4.0

Lift truck repairs

 Lift trucks under repair shall be locked and tagged as out of service.
 It is prohibited to provide repairs and maintenance of lift trucks in work areas.
 All repairs shall be performed only at designated maintenance & repair shops.

Note: In case of breakdown repairs can be done on site but only after agreed mitigations have been put
in place.

PPE requirements

Lift truck operators shall use proper PPE specified in the PIL PPE Procedure.

Lift truck documentation

Each lift truck shall be provided with the following documentation:

 Lift truck pass;
 Lift truck operation manual;
 Certificate of annual inspection conducted by a Qualified Crane, Rigging and Lifting inspector from
PIL approved company;
 Daily pre-work inspection checklist;
 Routing list (if applicable).

Annual lift truck inspection requirements

All lift trucks shall be annually inspected by a Qualified Crane, Rigging and Lifting Inspector from a PIL
approved Company. Lift truck owners are responsible for arranging for, and providing, annual technical
inspections of their lift trucks.

Forklifts shall be marked with the current annual color code once the annual inspection is completed.

Each color code shall last for a period of twelve (12) months. The color code for all lifting devices and
equipment for the current year is posted on relevant notice boards.
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Copies of the manufacturer’s operation manual for each type and model of a lift truck shall be maintained
and be available in the Supervisors’ office.

11 TRAINING REQUIREMENTS.

All lift truck operators shall have:

 Approved Operator Certificate.
 PIL Man Machine Interface Training

Note: The training materials shall describe safety and health requirements when operating a forklift truck
as defined by the procedure.

12 ADMINISTRATION OF SAFETY PROCEDURE

Safety Procedure Owner

PIL Project HSSE Manager is responsible for making necessary changes in the main document and its
appendices.

Revision Cycle

This Instruction shall be reviewed and updated, as necessary, based on trends and lessons learned on the
Project.
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Appendix 1. Operator's Daily Checklist - Electric Industrial Truck

Record of Fluid Added

Date Operator Battery Water

Truck# Model# Hydraulic Oil
Department Serial#
Shift Drive Hour Meter Reading Hoist Hour Meter Reading

SAFETY AND OPERATIONAL CHECKS (PRIOR TO EACH SHIFT)

Have a qualified mechanic correct all problems.

Motor Off Checks OK Maintenance

Leaks – Hydraulic Oil, Battery
Tires – Condition and Pressure
Forks, Top Clip Retaining Pin and Heel -- Condition
Load Backrest Extension – Attached
Hydraulic Hoses, Mast Chains, Cables & Stops – Check Visually
Finger Guards – Attached
Overhead Guard – Attached
Safety Warnings – Attached (Refer to Parts Manual for Location)
Battery – Water/Electrolyte Level and Charge
Hydraulic Fluid Level – Dipstick
Transmission Fluid Level – Dipstick
Operator's Manual in Container
Capacity Plate Attached – Information Matches Model, Serial Number and Attachments
Battery Restraint System – Adjust and Fasten
Operator Protection
Sitdown Truck - Seat Belt – Functioning Smoothly
Man-up Truck – Fall protection/Restraining means - Functioning
Brake Fluid – Check level
Motor On Checks (Unusual Noises Must Be Investigated Immediately) OK Maintenance
Accelerator Linkage – Functioning Smoothly
Parking Brake – Functioning Smoothly
Service Brake – Functioning Smoothly
Steering Operation – Functioning Smoothly
Drive Control – Forward/Reverse – Functioning Smoothly
Tilt Control – Forward and Back – Functioning Smoothly
Hoist and Lowering Control – Functioning Smoothly
Attachment Control – Operation
Horn – Functioning
Lights & Alarms (where present) – Functioning
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Hour Meter – Functioning

Battery Discharge Indicator – Functioning
Instrument Monitors – Functioning

ALL OPERATORS MUST BE TRAINED AND EVALUATED ON THE TYPES OF INDUSTRIAL TRUCKS
AND ATTACHMENTS THEY WILL BE OPERATING.