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TABLE OF CONTENTS

Purpose/Goal……………………………………………………………………………..3Scope……………………………………………………………………………………….3Responsibilities…………………………………………………………………………..4Vehicle Requirements…………………………………………………………………..4Training…………………………………………………………………………………....5Safe Operation, Traveling, and Loading…………………………………………….6Forklift Pre-Use Inspections………………………………………………………….8Preventative Maintenance for Powered Industrial Trucks…………………….8Fuel/Battery Handling, Storage, and Filling……………………………………….9Recordkeeping…………………………………………………………………………….9Hazard Assessment……………………………………………………………………..9Annual Review…………………………………………………………………………….9

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POWERED INDUSTRIAL TRUCK

1. Purpose / Goal a. This program has been developed to reduce the risk of physical injury or

property damage in areas where powered industrial trucks are in operation. It also brings the facility into compliance with federal, state, and local law. This program supports compliance with the Occupational Safety and Health Administration PIT Standard as found in 29 CFR 1910.178.

2. Scopea. This program applies to the operation of all powered industrial trucks, forklifts,

tractors, scissor lift trucks, motorized hand trucks, and other specialized industrial trucks powered by electric motors or internal combustion engines by plant employees and contractors, engaged in plant projects.

i. Definitions : The following terms are associated with the design, type and use of powered industrial trucks.

1. Approved truck : A truck that is listed or approved for fire safety purposes for the intended use by a nationally recognized testing laboratory, using nationally recognized testing standards.

2. Designation : Refers to the truck’s power source and if the truck is equipped with any additional safeguards to the exhaust, fuel and/or electrical systems. The designation will also indicate any locations where the truck may not be used such as in atmospheres containing flammable vapors or dusts

3. Competent Operator : an employee that has successfully completed the classroom and hands-on training required by the program.

4. OSHA Certified Trainer : An individual who has been trained by an OSHA Certified Trainer. The training includes classroom training and hands-on for stand-up, sit down, and walk behind trucks.

5. Trained Trainer : Individuals who have successfully completed training given by the facilities OSHA Certified Trainers.

6. Other Trainers : Employees who have been given training on scissor lifts, genie-boom, and floor scrubbers.

7. Servicing and/or Preventative Maintenance : Per manufacturer’s guidelines, scheduled maintenance on each truck and docking system within the facility.

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8. Identification Plate : Contains information about the truck’s design and capacity including information about the truck’s engine, load capacity, serial number, weight and the truck’s type designation. The identification plate may also contain additional information specific to that type of truck.

9. Mast : The mechanism on the truck that raises and lowers the load. The mast is made up of a set of tracks that house bearings and chains.

10. Load Center : The distance from the heels of the forks to the load’s center of gravity.

11. Powered Pallet Jack : A type of powered industrial truck designed to move palletized materials. These trucks may be called walkie riders.

12. Counterbalance Forklifts : Designed for both indoor and outdoor use, counterbalance truck wheels as their center of gravity and can be powered by battery, propane, gasoline, or diesel fuel.

3. Responsibilitiesa. Program Element Leader : Bodee Capper, FLL, Shipping. This person is responsible for:

i. Maintain the overall integrity of the site Powered Industrial Truck Programii. Execute and/ or manage the execution of actions to implement and maintain

the program (risk assessments – evaluation-control)

iii. Train and develop site PE team members in their roles

iv. Train site personnel on PIT principles through delivery of General Awareness and support of / delivery of PIT operator training.

v. Evaluate potential changes in the site profile for PIT impacts

b. Program Coach : Matt McDaniel, HSE Specialist, HSE. This person is responsible for:i. Providing coaching and guidance to site personnel on implementation and

executionii. Providing technical guidance regarding Safety concepts and/or programming

c. Program Sponsor : Larry Brennecke, Director, RTE & Shipping. This person is responsible for:

i. Ensuring successful implementation and maintenance of program

ii. Providing Program Leader with adequate time and resources to manage the requirements of the program

iii. Executing actions to support or better the program

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iv. Eliminating any and all barriers preventing the successful execution of the program

d. Program Team Member: i. These Team Members are responsible for:

1. Executing actions such as risk assessments, developing risk control, training/communication,etc.

2. Providing technical support to HSE Team regarding maintenance activity, inspection/PM, equipment operation or function, and required tasks or interactions

a. Nick Hirth, BUL, RTE HP. b. Michael Kearney , Planner, HOTS. c. Bill Kula , Team Leader, Maintenance. d. Zach Swanger , Planner, COBE.

4. Vehicle Requirements a. All forklifts and powered industrial trucks are designed and constructed to meet

minimum American National Standards Institute (ANSI) requirements established in the “American National Standard for Powered Industrial Trucks, Part II, ANSI B56.1-1969.

b. All forklifts and industrial trucks are marked with a nameplate identifying its approval under ANSI B56.1-1969.

c. Additional information on the nameplate includes the designation of the industrial truck as outlined in Table 1.

d. If a forklift or industrial truck is used in an area containing potentially hazardous atmospheric conditions, it is the responsibility of the operator and supervisor to ensure the correct forklift designation is available for use. Any operation of a forklift in a potentially hazardous atmosphere should be approved by the Office of Environmental Health & Safety.

Designation Description“D” Diesel engine powered“DS” Diesel engine powered with

additional safeguards to the exhaust, fuel and electrical systems

“DY” Diesel engine powered with the safeguards of the DS units AND do not have any electrical equipment and are equipped with temperature limitation features

“E” Electrically powered“ES” Electrically powered with

Table 1

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additional safeguards to prevent emission of hazardous sparks

“EE” Electrically powered with the safeguards of ES units AND all electrical equipment is completely enclosed

“EX” Electrically powered with the safeguards of ES and EE, AND are constructed to be used in atmospheres containing flammable vapors or dusts

“G” Gasoline engine powered

“GS” Gasoline powered with additional safeguards to the exhaust, fuel and electrical systems

“LP” Liquefied petroleum gas powered

“LPS” Liquefied petroleum gas powered with additionalsafeguards to exhaust, fuel and electrical systems

5. Traininga. Initial Training: Supervisors ensure all forklift operators are adequately trained prior to

operating a forklift/industrial truck. Training must consist of both formal instruction and practical evaluation.

i. Formal instruction includes lecture or online and includes the following elements:

1. Specific operating instructions, warnings, limitations, and precautions specific to the type of industrial truck to be utilized by the operator;

2. Differences between the forklift/industrial truck and a vehicle;

3. Equipment controls and instrumentation including their location and proper operation;

4. Operating the motor/engine;

5. Steering and maneuverability;

6. Visibility, including limitations when loading/unloading;

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7. Fork use and attachment adaptation, operation and limitations;

8. Vehicle capacity and stability limitations;

9. Completing equipment pre-use inspections;

10. Refueling and/or battery changing/charging; and

11. Specific workplace operation of the forklift including the following.i. Handling loads specific to the operation of the

forklift/industrial truck;

ii. Operating in narrow aisles and/or around pedestrian traffic;

iii. Ventilation while using forklifts; and

iv. Use restrictions based on hazardous locations.

b. Practical evaluation includes demonstration performed by the trainer and practical exercises performed by the trainee in order to ensure competence by the operator when utilizing an industrial truck.

i. Practical evaluation is conducted utilizing the industrial truck to be used by the operator.

ii. Practical evaluation must simulate typical work to be conducted with the industrial truck and may consist of the following;

1. Performing pre-use inspections

2. Safe operation of the industrial truck

3. Handling a load

4. Maneuverability

c. Refresher training: Refresher training may be necessary due to certain circumstances:i. The operator is observed operating the vehicle in an unsafe manner;

ii. The operator is involved in an accident or near-miss incident;

iii. The operator receives an evaluation revealing unsafe practices;

iv. There is a change in workplace conditions affecting operation of an industrial truck;

v. There is a change in the type of industrial truck being utilized in the workplace.

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d. Certification: Forklift/Industrial truck operators are certified by an OSHA Certified trainer or trained trainer. This certification is documented and includes the following.

i. Operator name

ii. Date of training

iii. Date of evaluation

iv. Trainer name

e. OSHA Certified Trainers have successfully completed a third party PIT classroom and practical evaluation.

f. Operator Trainers have successfully completed classroom and a practical evaluation by an OSHA Certified Trainer.

g. Forklift/Industrial Truck operators are recertified every 3 years.

h. Forklift/Industrial Truck OSHA Trainers are recertified every 5 years.

6. Safe Operation, Traveling, and Loadinga. Operation of a forklift/industrial truck is done in a safe manner to prevent injury to the

operator or pedestrians in the area; and to prevent damage to property during operation. Safe operation of a forklift/industrial truck includes the following practices.

i. Trucks shall not be driven up to anyone standing in front of a fixed object.

ii. Seatbelts are worn at all times.

iii. Passing under a raised load or other elevated portion of a truck is prohibited.

iv. Unauthorized persons shall not “ride” on a forklift unless the forklift is equipped with a proper passenger area.

v. Operators shall keep hands and feet inside the forklift at all times.

vi. When left unattended, forklift load engaging means shall be in the lowered position, controls neutralized, power shut down, and brakes set. If parked on an incline, wheels shall be blocked.

1. A forklift/industrial truck is considered unattended when the operator is 25 feet, or more, away from the truck or whenever the truck is not in direct view of the operator.

2. If an operator dismounts a forklift and remains within 25 feet or the truck, the forks shall be lowered, controls neutralized, and brakes set to prevent movement.

vii. Maintain a safe distance from edges of ramps or platforms

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viii. Forks shall not be used for purposes other than those specified by the truck manufacturer such as opening doors, raising persons to elevated areas, etc.

ix. Ensure sufficient head room under overhead installations such as lights, sprinklers, pipes, etc.

x. An overhead guard shall be in place on the truck to provide protection against falling objects.

xi. Only approved industrial trucks shall be used in hazardous locations.

xii. Ensure aisles, passage ways, and access to fire equipment and emergency exits remain clear at all times.

xiii. If at any time a forklift/industrial truck is found to be in need of repair, defective, or in any way unsafe, the truck is immediately taken out of service until it is restored to safe operating condition.

xiv. Lighting shall be sufficient to ensure safe operation of a forklift/industrial truck. 1. If general facility lighting is insufficient (less than 2 lumens per square

foot) auxiliary lighting must be provided on the forklift.

xv. Ventilation shall be sufficient to prevent the accumulation of gases from petroleum powered industrial trucks.

b. Safe traveling while operating a forklift/industrial truck is essential to maintaining a safe workplace. The following traveling safety points shall be implemented to the operation of trucks.

i. Observe all traffic regulations while operating a forklift including speed limits.

ii. The right of way shall be yielded to ambulances, fire trucks or other emergency vehicle.

iii. Other trucks shall not be passed when traveling in the same direction.

iv. When approaching an intersection at aisles and other locations, the operator shall slow down, sound the horn, and ensure no pedestrians or other trucks are in the area.

v. Forklifts/industrial trucks shall be driven forward unless the lad being carried obstructs the view, in which case the forklift shall be driven in reverse.

vi. Cross railroad tracks diagonally.

vii. Always ascend/descend grades slowly.1. If traveling on an incline greater than 10%, the load shall be maintained

upgrade to prevent tipping.

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viii. When traveling with a load, the fords shall be tilted back and raised only enough to provide clearance in the direction of travel.

ix. Stunt driving and horseplay is prohibited.

x. Maintain a safe operating speed at all times including when operating on wet/slippery floors, while negotiating turns; and when operating around other trucks/pedestrians.

xi. Ensure no debris or loose objects are in the path of travel.

xii. Dock boards/bridge plates shall be secured in place prior to traveling over them.

xiii. Caution is taken when loading and unloading trucks/trailers with industrial trucks/forklifts. The following precautions are taken to prevent accidents, injuries, and/or property damage during loading and unloading events.

1. Loads to be handled are stable and safely arranged to permit safe handling.

2. Ensure the rated capacity of the industrial truck/forklift is not exceeded by the load to be handled.

3. When picking up a load, the load engaging means (forks) shall be placed under th3e load as far as possible and the mast tilted backward to stabilize the load.

4. Use extreme care when tilting loads backward and forward, especially during high tier movement and/or storage.

5. When loading/unloading trucks/trailers, ensure the truck/trailer brakes are set and wheels blocked to prevent movement. Fixed jacks must be placed securely under trailer.

6. The flooring within trailers shall be sufficient to support the loads as well as the industrial truck/forklift being utilized to load/unload the trailer.

7. Pre-Use Forklift Inspectionsa. Prior to the use of a forklift/industrial truck by an operator, a pre-use inspection must be

completed to ensure safe operation of the equipment at all times. i. Pre-use applies to each shift when multiple shifts are in place utilizing the

equipment.

b. The pre-use inspection checklist includes the following general items:i. Identification of the industrial truck/forklift

ii. Name of person conducting the inspection

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iii. Date/Time of inspection

iv. Inspection of equipment condition when not powered on

v. Inspection of equipment operation and controls when powered on.

c. Appendix A provides a sample pre-use inspection checklist for use on most forklifts/industrial trucks.

d. If at any time a deficiency is noted during the pre-use inspection, the forklift/industrial truck shall be removed from service and repaired by an authorized mechanic prior to being placed back into operation.

i. Lock out the industrial truck, notify the FLL, and write a work order for repair.

ii. Inspection documents should be maintained by the department supervisor, or their designee, for recordkeeping purposes.

iii. Each Period the documents are to be handed to the HSE representative for filing.

8. Preventative Maintenance of Forklifts/Industrial Trucksa. Any forklift/industrial truck found not safe for operation must be immediately removed

form service under this program.

b. Maintenance to be conducted on any forklift/industrial truck shall not be performed in a hazardous location (Class I, II, and III)

c. Utilize Lockout/Tagout procedures to control hazardous energy sources during maintenance operations.

d. All repairs shall be made by an authorized service technician.

e. Forklifts/industrial trucks shall be deemed safe for operation following all maintenance activities.

9. Fuel/Battery Handling, Storage, and Fillinga. Batteries

i. Facilities utilizing battery powered forklifts/industrial trucks shall have clearly designated battery charging areas within the facility.

1. Equipment shall be provided at the charging stations to allow for flushing and neutralizing spilled electrolyte, fire protection, and adequate ventilation.

ii. Sufficient means for handling batteries must be provided based on the types of batteries being utilized at the facility.

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iii. Smoking is not permitted in battery charging/changing areas.

iv. When charging batteries, acid shall be poured into water, water shall not be poured into acid.

10. Record Keepinga. Department supervisors shall maintain documentation of the following:

i. Training certifications for all forklift/industrial truck operators including names and dates of training; and the equipment they are certified to operate.

ii. Pre-use inspection checklist

iii. Maintenance records for each forklift/industrial truck.

iv. Accident reports involving forklifts/industrial trucks.

11. Hazard Assessmenta. Every area where a powered industrial truck operates or can operate will require a

hazard assessment.i. Identify the areas by using a building layout.

ii. Include pictures to capture the findings of the assessment.

iii. Utilize the hazard assessment form to identify and score each hazard. Then identify what controls to put in place.

1. Important to identify atmospheric hazards a fork truck may work in. Combustible dust, vapors, gases, or fibers are some common hazards to look for.

12. Annual Reviewa. The Program Element Team will review and evaluate the effectiveness of this program

when any of the following occursi. On an annual basis using the Powered Industrial Truck Safety Checklist provided

in the Appendix.

ii. When changes occur to the OSHA Powered Industrial Truck Standard that requires a revision to this program.

iii. When changes occur to related procedures that require a revision.

iv. When facility operational changes occur that requires a revision.

v. When there is an accident or near miss that relates to this area of safety.

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Revision Date Description of Changes1) 8/24/15 Initial release2) 9/1/2015 Seat belts worn at all times.3) 10/20/2015 Certified and operator training definition

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Appendix A

Powered Industrial TruckSafety Checklist

(See CFR 1910.178)

Vehicle Type/Use1. Do all powered industrial trucks meet the design and construction requirements of ANSI B56.1-

1969,2. American National Standard for Powered Industrial Trucks? Yes______ No______3. Are modifications and additions that affect the capacity and safe operation of the vehicle

performed only with the manufacturer's prior written approval? Yes______ No______4. If modifications or additions are performed, are the capacities, operation, and maintenance

instruction plates or decals changed accordingly? Yes______ No______5. Are nameplates and markings in place and legible? Yes______ No______6. Is the proper type of truck being used for particular locations as required by Table N-1178 on

atmospheric hazards? Yes______ No______7. Are trucks fitted with an overhead guard if needed (unless operating conditions do not permit)?

Yes______ No______8. Are trucks equipped with a vertical load backrest extension if the type of load presents a

hazard? Yes______ No______9. Is fuel handling and storage in accordance with NFPA No. 30-1969, Flammable and Combustible

Liquids Code, and NFPA No. 58-1969, Storage and Handling of Liquefied Petroleum Gases? Yes______ No______ N/A

Changing and Charging of Batteries1. Are batteries changed and charged in specifically designated areas? Yes______ No______2. Are facilities provided for flushing and neutralizing spilled electrolyte? Yes______ No______3. Is fire protection and adequate ventilation provided? Yes______ No______4. Is adequate battery handling equipment provided? Yes______ No______5. Are reinstalled batteries properly positioned and secured? Yes______ No______6. Is a carboy tilter or siphon provided for handling electrolyte? Yes______ No______7. Are precautions taken not to pour acid into water or water into acid? Yes______ No______8. Are truck brakes applied before batteries are changed or charged? Yes______ No______9. Are vent caps in place when charging? Yes______ No______10. Are battery compartment covers open when charging? Yes______ No______11. Is there a smoking prohibited sign posted in the charging area? Yes______ No______12. Are precautions taken to prevent flames, sparks, or electric arcs in the charging area? Yes______

No______13. Are tools and metallic objects kept away from the tops of uncovered batteries? Yes______

No______14. Is adequate lighting provided in operating areas? Yes______ No______General Safety Precaution/Rules1. Is adequate lighting provided in operating areas? Yes______ No______

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2. Are concentrations of monoxide gas created by truck operations not in excess of the levels specified in 29 CFR 1910.93? Yes______ No______

3. Are brakes set and wheel chocks placed under the rear wheels of truck trailers? Yes______ No______

4. Are fixed jacks used (when necessary) on semi-trailers when not coupled to the tractor? Yes______ No______

5. Do operators avoid driving their truck up to anyone standing in front of a bench or other fixed object? Yes______ No______

6. Are pedestrians and other workers not permitted to stand or pass underneath the elevated portion of the truck? Yes______ No______

7. Are unauthorized persons not permitted to ride on trucks? Yes______ No______8. Do drivers keep their arms or legs inside the running lines of the truck? Yes______ No______9. If trucks are unattended, are the forks fully lowered, the controls neutralized, the power shut off

and the brakes set? Yes______ No______10. Do drivers maintain a safe distance from the edge of ramps or platforms? Yes______ No______11. Do drivers check the flooring of trucks, trailers for breaks and weaknesses? Yes______

No______12. Do drivers leave sufficient headroom (at least 18 inches) under overhead obstructions?

Yes______ No______13. Are all traffic regulations observed? Yes______ No______14. Do drivers maintain a safe distance (at least 3 truck lengths) from the truck ahead? Yes______

No______15. Do drivers avoid passing other vehicles at intersections, blind spots or other dangerous

locations? Yes______ No______16. Do drivers slow down and sound the horn at cross aisles and where vision is obstructed?

Yes______ No______17. If the load obstructs the view, do drivers travel with the load trailing? Yes______ No______18. Do drivers always look in direction of path of travel? Yes______ No______19. Do drivers ascend and descend grades slowly? Yes______ No______20. Do drivers keep the load engaging means facing downgrade if the truck is unloaded? Yes______

No______21. Do drivers tilt the load back on grades (if possible) and raise the load only enough to clear the

road surface? Yes______ No______ 22. Do drivers slow down for wet and slippery floors? Yes______ No______23. Are trucks driven carefully and slowly over dockboards and bridgeplates? Yes______ No______24. Do drivers properly secure bridgeplates and check their rated capacity? Yes______ No______25. Do drivers approach elevators slowly and enter squarely after the elevator is properly leveled?

Yes______ No______26. Once inside the elevator, do drivers neutralize the controls, shut off the power and set brakes?

Yes______ No______27. Do drivers reduce speed while negotiating turns? Yes______ No______

Loading Powered Industrial Trucks1. Are loads stable and safely arranged? Yes______ No______2. Are loads always within rated capacity of the truck? Yes______ No______3. Are long or high loads that may affect the truck's capacity properly adjusted? Yes______

No______4. When attachments are used, do drivers take extra care to secure, position and/or transport the

load? Yes______ No______

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5. Is the load engaging means is placed as far under the load as possible, and the mast carefully tilted to stabilize the load? Yes______ No______

6. Are elevated loads not tilted forward except to deposit the load? Yes______ No______Inspection/Fueling/Maintenance

1. Are trucks that need repair immediately removed from service? Yes______ No______2. Are fuel tanks not filled when the engine is running? Yes______ No______3. Are fuel system leaks corrected before truck is operated? Yes______ No______4. Are repairs are made only by authorized personnel? Yes______ No______5. Are repairs involving fire hazards performed only in designated locations? Yes______ No______ 6. Is the battery disconnected before repairing the electrical system? Yes______ No______7. Are replacement parts equivalent to the original? Yes______ No______8. Are drivers or other personnel restricted from attaching additional counter weights to trucks

unless approved by the manufacturer? Yes______ No______9. Are trucks examined daily before being placed into service? Yes______ No _____.10. If used around-the-clock, are trucks are examined after each shift? Yes______ No______11. Are vehicles that overheat or emit sparks or flames from the exhaust removed from service?

Yes______ No______12. Are vehicles kept clean and free of excess oil and grease? Yes______ No______

Driver Training1. Have all drivers received formal instruction and practical training from a qualified instructor in

accordance with 1910.178(l)? Yes______ No______2. Have all drivers passed a performance test within the last three years? Yes______ No______

Corrective action taken if needed:_________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Completed By: _____________________________________ Date: _____________