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1 SUNCOR ENERGY PRODUCTS DISTRIBUTION TERMINAL OPERATING MANUAL STANDARD OPERATING PROCEDURE SAFEWORK PRACTICES Date Issued: June 2010 Revision Date: February 2013 Review Date: February 2016 Revision # PURPOSE A forklift is a small industrial vehicle featuring a projected fork which is inserted under the load to lift and move it from one place to another. Forklifts are most commonly used in factories and huge warehouses, where huge loads have to be moved regularly. These machines prove to be very useful when it comes to loading or unloading goods, to or from other carriers. Most of the forklift accidents which take place are attributed to inadequate training provided to the operators, or their inexperience in handling such machines. A forklift overturning from an upright position is the most common cause of accidents, wherein either the operator himself or another worker is caught below the machine. Many a times the workers working around also injure themselves by coming in between this machine and load or wall. In a few cases, people get injured or even lose their lives after being run over by the machine. Though rare, some accidents also include an individual being caught between two machines as well. Sometimes, workers also get injured due to some load falling on them, or they themselves falling on the fork. The purpose of this document is to define and communicate the elements of safe forklift handling to Suncor Personnel and applicable Contractors working within Distribution. Forklift Safety Page 1 of 13

2 2.0 SCOPE This document applies to Suncor Personnel and Contractors who are working within Distribution Terminals. References in this document to Suncor Personnel include directors, officers, employees, contract workers, consultants and agents of Suncor. This procedure applies to all Distribution Personnel and Contractors who are required as part of their regular job function to operate a forklift. This Standard Operating Procedure applies to all forklifts. 3.0 REFERENCED DOCUMENTS WorkSafe BC Part 16 Saskatchewan Occupational Health and Safety regulations, Part XII Alberta Occupational Health and Safety Code, Part 19 Ontario Regulation 851, Section 45 Quebec Occupational Health & Safety Code, Division XXIII 4.0 PRECAUTIONARY STATEMENTS 4.1 Training All persons who are required to operate forklifts MUST as part of their job function, must possess a training certificate issued by a recognized training facility. It is further required forklift operators undergo refresher training on forklift operation at an interval level of no more than 3 years. Forklift Safety Page 2

3 4.2 Specific Hazards Typical hazards that may be encountered while operating a fork lift may include; Work Environment Hazards Slips or Trips Possible Position of Hands, Pinch Points Ergonomic Hazards Awkward Body Position Walk Area Not Clear / Level Uneven Terrain Parts of Body in Line of Fire Equipment Hazards Operating Power Equipment Specialized Equipment / Tools Personal Limitations Distractions in Work Area No Training for Tools to be Used 4.3 Personal Protective Equipment Personal protective equipment as outlined in Distribution Standard Operating Procedure, Cat A-1, SOP #10 or as specified in the Safe Work Permit depending on the work to be completed as per the job scope requirements. All forklifts must be outfitted with a working seat belt which must be used at all times when the forklift is operational. Forklift Safety Page 3

4 5.0 ROLES & RESPONSIBILITIES Terminal Management; Accountable to ensure full implementation and compliance of this standard operating procedure. Responsible to ensure all equipment is maintained and inspected as per required with this standard. Responsible to complete regular audits of forklift activities and document findings in Suncor reporting tool. Responsible to ensure all Terminal Employees and Contractors who are required to use forklifts as part of their normal job function are verified for competency on a regular basis. Operating Authority / Performing Authority; Responsible to ensure full compliance with this procedure. Responsible to ensure pre-operation check list is completed in full. Responsible to ensure all equipment defects are reported to Terminal Management immediately. 6.0 SUSTAINMENT AND CONTINUAL IMPROVEMENT This document is classified in Process Safety terms as a Safework Practice Procedure and as such must comply with the Safework Practice Procedure Standard as outlined in Distribution Procedure Program, Cat B-3, SOP #14. Edmonton Terminal Management is to initiate document review process. To ensure this Standard Operating Procedure documents meets all applicable OEMS / PSM standards, this document is to be reviewed at a frequency not to exceed 3 years or when conditions change to warrant a review Forklift Safety Page 4

5 7.0 Forklift Safety Tips Forklift operations may sometimes lead to physical hazards for the workers as well as the operator himself. These hazards may range from minor injuries to severe injury, eventually resulting in death. There are some basic rules advocating forklift safety, which include lawful riding, speed limits, unauthorized operations, proper signals and load carrying capacity. Most often, accidents occur when these rules are not followed properly. a. A forklift must be equipped with a seatbelt. The use of is mandatory for the operator. b. Only drivers who have attained training in safe operation of such machines should be permitted to operate forklifts. c. The machines should be properly checked every day or when the operator changes. If any problem persists in the forklift it must be promptly attended to. Never operate unsafe machine as you may put yourself as well as other people's lives at risk. d. You should continuously monitor the direction in which the machine is heading. While turning, you must stop and have a look, and move only when everything is clear. e. Give necessary signals, such as sounding the horn when approaching an area where people are working. More importantly, the driver has to follow the basic regulations such as the speed limit. f. Never try to raise or lower the load while the machine is on the move. Drive at the restricted speed while the forks are loaded. g. The driver shouldn't carry riders unless the vehicle has a passenger seat. NEVER allow people to ride on the machine, especially on the forks. h. Know the lifting capacity of the forklift and NEVER exceed the manufacturers operating capacity of the machine. Forklift Safety Page 5

6 i. Ensure the load on the fork is properly balanced. j. When traveling with the forks empty, make sure they are lowered and tilted back. k. When using fork extenders, consideration must be given to the alteration in the forklift s center of gravity. l. Extra precautions need to be taken when working on a ramp or congested area. Never try to turn on ramps. m. Keep an eye on overhead clearance as well. n. When not in use, the machine should be properly switched off. The parking brake should be set and the forks should be lowered completely. In addition, pressurized fuel systems should be turned off and a battery disconnect switch turned to the off position. o. DO NOT allow any workers around a forklift while in operation. p. When the machine is in motion, a. keep the load as low as possible, (to keep the centre of gravity as low as possible.) b. be sure to maintain visibility in the direction of travel. When the load obsures visibility, obtain the assistance of a fellow employee to provide direction assistance before the forklift is placed into motion. c. When lifting loads to high positions, a) Do not allow observers to stand beside the load b) If the opposite side of the platform is open (as in pallet racking) ensure to have other workers vacate this area to avoid them being hit by a falling object. Forklift Safety Page 6

7 c) the forklift must be equipped with a protective cage, on the load side of the machine to prevent the operator from being struck by falling objects from the load. d. NEVER increase the lifting capacity of a forklift by increasing the size of the counterweight on the back of the machine. This situation creates a very unsafe situation because the size of the original counterweight is engineered in coordination with the original lifting capacity of the hydraulic system. e. All forklifts must be equipped with an automatic back-up alarm in good working condition. 8.0 HOW TO PREVENT A FORKLIFT FROM TIPPING OVER a. Ensure terrain is level and of good compaction / stability. b. Ensure the load is balanced c. Drive with the load in it s lowest position d. Take extra care when working on ramps, uneven or sloping surfaces e. Use extra caution when making sharp turns. f. Slow down when turning corners to prevent the load from shifting If the forklift begins to tip: a. Stay in the seat DO NOT attempt to jump clear b. Hold on tightly to the steering wheel and brace yourself against the seat. c. Keep your body inside the frame of the machine, and lean in the opposite direction of the over-turn. Forklift Safety Page 7

8 9.0 SAFE USE OF FORKLIFTS AROUND OTHER WORKERS a. Slow down and sound the horn where vision is obstructed. b. Never let a person get between the forklift and a hard surface such as a wall table, bench or other fixed object. c. Never let a person walk or stand under the raised forks or load. d. Stop when anyone crosses the route being followed, lower the load and wait until the path is clear. e. DO NOT raise the forks while the machine is moving. f. Look toward the path and keep it in clear view. g. Drive at a speed that permits safe stopping. h. Keep a safe zone around the forklift when equipment is being lifted. i. Never allow observers, or fellow workers too stand beside the load when it is being elevated. Workers, other than the operator should only be permitted to stand beside the operator or in such a position that, should all or any part of the load fall, that no part of the falling load should have a chance of striking the observer. Ensuring that all workers are clear is the responsibility of the forklift operator FORKLIFT SAFE DRIVING a. Keep your arms, legs, head and feet inside the forklift when driving. b. Drive at a speed that is safe for the driving surface, workplace and load conditions c. Back down all grades when loaded d. Make a complete stop at doors, corners and exits. Sound the horn and continue slowly. e. Watch for overhead obstructions f. Avoid turning on ramps and inclines. g. Maintain a safe distance from the edge of ramps, docks and loading platforms. h. Cross railway tracks on the diagonal to prevent wheel damage and to keep the load from shifting. i. Keep to the right when driving unless layout or conditions warrant otherwise. j. Do not enter a trailer unless the wheels are chocked or secured with a trailer locking mechanism. k. When more then one forklift is operating in proximity to one another create a work plan Forklift Safety Page 8

9 so that every operator knows where they are expected to yield. Review this plan on a regular basis CARRYING THE LOAD SAFELY a. Move only when you are sure the load is stable b. Drive with the load against the backrest with the mast tilted back. c. Carry the load as low as possible d. Operate the forklift in reverse if the load obstructs your view or get the assistance of a fellow worker to escort the driver and machine while the machine is in motion. e. Avoid sudden starts and stops USING THE FORKIFT AS A WORK PLATFORM a. Lift workers only in an approved and properly secured personnel cage. b. Do not move the forklift when workers are working on the forklift s elevated platform. c. Platform must be securely fastened to the load basket. d. Never lift a person on the forks or a pallet or other load SAFE LOADING AND UNLOADING a. Straighten wheels when picking up or dropping a load. b. Keep within the load capacity of the forklift. c. Space the forks correctly to support the load. d. Place the forks as far as possible under the load. e. Forks must be placed evenly from the centre stringer of a pallet. Forklift Safety Page 9

10 14.0 LEAVING THE FORKLIFT a. When leaving the forklift, straighten the wheels. b. No load shall be left in the raised position with the forklift unattended. c. Never park on an incline. d. To avoid a tripping hazard, i. Tilt fork with no load forward with the tips touching the ground. ii. Lower stable loads flat to the ground. e. Put the forklift controls in neutral f. Apply the handbrakes g. Turn off the motor ( if leaving unattended ). h. Turn off the fuel (especially if a pressurized fuel is used) and place the switch on the starting circuit (Night switch) in the off position 15.0 ANNUAL INSPECTIONS At least annually, each forklift must be Inspected thoroughly. The examination must be completed by a competent person. Inspection may include non destructive testing such as Magnetic Particle Inspection. Any deficiencies arising from the annual inspection, MUST be completed, prior to the forklift being returned for regular service. At a minimum the annual inspection must include: a. Forks and Carriage b. Attachments c. Operational Test d. Lift Chains e. Hydraulic Hoses f. Body and Counterweight Attachment g. Elevation Cylinders h. Tilt Cylinders i. Mast Sections Forklift Safety Page 10

11 j. Overhead Guard k. Safety and Warning Devices l. Tires, Battery, Brakes m. All pins, bolts, welds and fasteners. n. Pressurized fuel tanks (propane etc.) should be re-tested and certified on a regular basis in accordance with the manufactures requirements Certificate of Inspection must be retained on file PROCEDURAL DEVIATION Deviations from this standard operating procedure must be authorized using the Management of Change procedure. Deviations must be documented and documentation must include the relevant facts supporting the deviation decision Forklift Safety Page 11

12 DATE AUTHOR DESCRIPTION REVISION June, 2010 R. Rattray New document issue. Initial Issue February 2013 R. Rattray Document reviewed, no changes required Forklift Safety Page 12

13 FORKLIFT DAILY INSPECTION REPORT LOCATION: DATE: FORKLIFT ID: TIME: FORKLIFT INSPECTION ( KEY OFF ) Visual Inspection of : YES NO N/A Overhead Guard Hydraulic Cylinder Leaks Mast Assembly Lift Chains & Rollers Forks Tire Condition LPG Tank Hose Propane Leaks LPG Tank certification Valid LPG Tank WHMIS Identified? LPG Cylinder securely attached Gas Gauge Tire Condition Protective Cage All Fluid Levels hydraulic and coolant crankcase oil Battery corrosion - leakage Steering Column Seat Safety Belt Certification / Manufacturer Plate FORKLIFT INSPECTION ( KEY ON ) Visual Inspection of : YES NO N/A Oil Pressure Indicator Lamp Battery Discharge Meter Ammeter Indicator Lamp Hour Meter Water Temperature Gauge Test Standard Equipment: YES NO N/A Steering Brakes Front / Tail / Brake Lights Horn Hydraulic Function of Lifting Operation Back Up Alarm Parking Brake Other Operator Qualifications YES NO N/A Trained & Competent Action Taken, Circle One: Placed into service Taken Out of service Forklift checklist is to be used daily when in use No forklift is to be used unless all above criteria are met. Any deficiencies MUST be repaired prior to use. Date Operator Name ( print ) Operator Name ( signature )

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