TVA - TSP-18.805 Forklift Operations Assessment

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Personnel

Basic requirements for Forklifts (Section 1)

Are forklifts labeled with manufacturers name, type, model, serial number, capacity, operation, and maintenance instruction plates, tags, or decals? Explanation: All forklifts purchased, leased, rented, and used by TVA plants/facilities must adhere to design and construction requirements of ANSI B56.1 “Safety Standard for Low Lift and High Lift Trucks”
Are truck data and capacity plates in place? Explanation: Forklifts are not to be used if the “truck data and capacity plate” is missing or illegible.)
Are forklifts selected based on their NFPA designation? Explanation: NFPA Categories: • Gasoline Powered (G) (GS); • Diesel Powered (D) (DS) (DY); • Liquefied Petroleum Gas Powered (LP) (LPS); • Electric Powered (E) (ES) (EE) (EX).
Are only forklifts with the designation EX used in coal handling operations? Explanation: (Coal handling areas meet hazardous classification Class II, Division 2)
Are only forklifts designated DY, EE, or EX used in volatile flammable liquids or flammable gases? Explanation: Volatile flammable liquids or flammable gases meet the hazardous classification of Class I, Division 2.
Are only forklifts designated DY, EE, or EX used in volatile flammable liquids or flammable gases? Explanation: Volatile flammable liquids or flammable gases meet the hazardous classification of Class I, Division 2.
Are forklifts equipped with lights? Explanation: When lighting is less than two-foot candles, trucks will be equipped with lights.
Are modifications/attachments that affect the capacity and safe operation approved by the manufacturer? Explanation: Modifications/attachments are to be approved in writing by the manufacturer. Capacity, operation, and maintenance instruction plates, tags, or decals are to be changed accordingly.
Are removable attachments (other than fork extensions) equipped with nameplates with information indicating “the forklift/attachment combination may be less than the capacity shown on the attachment - consult truck nameplate”?

Lift Truck Operations (Section 2)

Are only trained and certified employees operating lift trucks? Explanation: The operator is responsible for the safety of the lift and has the authority to stop work to correct safety issues.
Are lift trucks inspected prior to being placed into service?
Are loads transported properly? Explanation: • Do not overload a forklift (ignoring load capacity placards) ; • Never drive or transport loads with a lift truck while the forks are higher than necessary to clear the road surface; • Observe regular traffic rules; • Only qualified operators; • Keep all extremities inside the cab; • Ensure employees keep a distance from the load to prevent them from being struck if load fell; • Do not move the forklift forward or reverse while people are on the platform.
Are bridge plates properly placed and secured when traveling onto trucks or rail cars from loading dock and platform?
When lift trucks are left unattended are the forks fully lowered, controls neutralized, power shut off, and brakes set? Explanation: A lift truck is considered unattended when the operator is 25 feet or more away from the vehicle which remains in his/her view or whenever the operator leaves the vehicle and it is not in his/her view
When necessary to use a lift truck as a work platform, is there a properly designed safety platform that can be securely attached to the forks?
When using a forklift for a below-the-tine lift are only manufactured lifting attachments used? Explanation: Free rigging (direct placement of rigging equipment onto the tines of the forklift) is prohibited.

Forklift Operating Areas (Section 3)

Are there established battery charging, refueling, and loading dock areas? Explanation: Mark areas for battery charging or refueling with caution signs to prohibit no open flames.
Are hazardous areas identified? Explanation: Hazards designate which lift truck to utilize. Hazards include: • Flammable gases; • Vapors; • Combustible dust; or, • Easily ignitable fibers.
Are aisles and areas for forklift operations designated and clearly marked? Explanation: Areas/aisles are to be established based on the evaluation of: • Maximum allowable floor loading • Adequate overhead and side clearances

Pre-operational Inspection of Forklift (Section 4)

Are aisles and areas for forklift operations designated and clearly marked? Explanation: Areas/aisles are to be established based on the evaluation of: • Maximum allowable floor loading • Adequate overhead and side clearances
Is maintenance notified when the forklift is in need of repairs or unsafe to operate? Is a defective equipment tag placed on the ignition until repaired?
Are operator’s daily inspection reports retained for 30 days?

Safe Forklift Operations (Section 5)

Are seatbelts provided and used?
Are all precautions taken to prevent tip-over accidents? Explanation: Slowing down before turning; Never turning on a slope; Driving with forks or attachment fully lowered and tilted back; Avoiding sharp turns; Moving slowly with raised loads; Not backing into low overheads with a raised load; No tilting heavy loads too far forward; Avoiding hard braking and sudden acceleration; No exceeding rated lifting capacity.
Are precautions taken to prevent the loss of loads? Explanation: Precautions to be taken: Do not handle double-tiered loads unless secured together.; When traveling up or down ramps or inclines, keep the load upgrade; Properly support the load; Keep the load as low as possible to the ground.
Are precautions taken to avoid injury? Explanation: Precautions to be taken: Keep legs and arms inside; Do not allow passengers on the forklift or forks; Do not allow people to pass under or be close enough to raised forks or load; Keep hands, feet, and legs out of the upright; Do not use the upright for a ladder; Watch for pedestrians; Sound horn at all intersections; If the load obstructs forward view, travel with the load trailing; Always look in the direction of travel.

Training & Certification of Forklift Operators (Section 6)

Are operators properly trained? Is retraining conducted every three years? Explanation: ATIS 00059122 “Forklift Operations”
Are operators issued and required to carry the TVA Certification Card? Explanation: TVA 18121

Preventative Maintenance on Forklifts (Section 7)

Are only authorized employees allowed to perform preventive/other maintenance, battery charging/changing, and inspections?
Are forklift maintenance manuals available?
Is there a regular maintenance schedule in place based upon manufacturer’s recommendations?
Are maintenance/inspection records kept for each forklift?
Are repairs made in a designated area? Explanation: No repairs shall be made in Class I, II, or III locations. Repairs to the fuel and ignition systems which involve fire hazards shall be conducted only in locations designated for such repairs.
Are forks inspected at 12 month intervals or when any defect or permanent deformation is detected? Explanation: Appendix A “Fork Inspection Criteria”
Are replacement parts equivalent in safety to the original design? Explanation: Replacement parts should not degrade the hazard class designation of the forklift.
Are counter weights approved by the forklift manufacturer via writing? Explanation: Forklifts shall not be altered from the original design of the manufacturer by the addition or removal of any parts. Additional counter weighting of forklift trucks shall not be done unless approved in writing by the truck manufacturer.
Are forklifts kept clean and free of excess coal dust, oil, and grease? Explanation: Only noncombustible or high flash point agents should be used for cleaning of trucks.

Refueling Operations (Section 8)

Is there a designated area for refueling?
Is there a fire extinguisher readily available?

Battery Charging/Changing (Section 9)

Is battery charging/changing conducted in a clearly marked designated area?
Are means provided for flushing and neutralizing spilled electrolyte, fire protection, protection of charging apparatus from damage and adequate ventilation/diffusion of gases in the charging area?
Are conveyors, overhead hoists, or equivalent available for handling equipment?
Are only trained and authorized employees changing or charging batteries?
Are eyewash/emergency shower facilities provided? Explanation: Eye wash / emergency shower facilities shall be provided within 25 feet of a battery changing area or where battery charging is performed that includes removing or refilling batteries
Are goggles or face shield, rubber gloves, and aprons available along with a carboy tilter or siphon for handling electrolyte?
Are NO SMOKING signs posted in the charging areas?

Jump-Starting Conventional 12 Volt Batteries (Section 10)

Prior to jump-starting a battery are the following steps completed: Protective goggles or face shield available; Removal of battery vent caps and covers with a cloth?
When jump starting a battery, are steps performed in the following sequence? Vehicles are not touching; Engine of charging vehicle running; Attachment of positive lead to positive terminal of discharge battery, then to positive terminal of the good battery; Attachment of negative lead to the negative terminal of the good battery; then to a metal part of the disabled forklift at a point away from the battery to avoid sparking near hydrogen gas; Removal of leads in reverse sequence.
Is protective equipment provided and used for battery removal?

Personnel Platforms (Section 11)

Are forklifts only used to lift personnel under the following requirements: Work platforms shall adhere to ANSI B56.1-1993 requirements; A slip-resistant floor surface; A minimum of 18 inches by 18 inches for each platform occupant; Protection for personnel in their normal working position; A guardrail between 36 and 42 inches including a midrail; A 4-inch height toe plate. The floor of the platform is not located more than 8 inches above the upper face of the forklift fork; Platform is secured to the lifting carriage or forks so to prevent it from pivoting upward; The combined weight of the platform, load, and personnel shall not exceed one-half of the capacity as indicated on the nameplate of the forklift on which the platform is used.
Is the following displayed on the platform: Maximum load (including personnel and equipment); Weight of empty platform; The minimum capacity of the forklift on which the platform can be used.
Is the following completed prior to lifting personnel: Platform secured to the lifting carriage or forks; Lifting mechanism lifted to entire height; Mast is vertical and not operating at a slope; Platform is horizontal and centered and not tilted forward or rearward; Forklift is on firm and level footing; Parking brake is applied and only released for minor maneuvering at the request of the elevated personnel; Area is marked with barrier tape.
Is the following adhered to during personnel lifting operations: Forklift operator lifts and lowers personnel with caution and only at their request; Overhead obstructions and electrical wires are avoided; Personnel remain on the platform; Personnel do not attempt to enter/exit until it has been lowered; Personnel do not attempt to enter/exit the platform by climbing on any part of the forklift.

Loading Dock Operations (Section 12)

Are brakes applied and wheel chocks or other positive means used to prevent unintentional movement to trucks/trailers before loading/unloading?
Are supports provided to prevent upending or corner dipping when forklifts are driven onto a semi-trailer not coupled to a tractor?
Are dockboards/bridge plates designed and maintained to allow for one end to come into contact with the dock and the other with the truck? Explanation: Substantial contact prevents the dockboard from rocking or sliding.
Do dockboards/bridge plates have a high friction surface designed to reduce the possibility of employees or forklifts slipping?
Are dockboards/bridge plates marked conspicuously with their rated carrying capacity?
Are portable dockboards/bridge plates secured in place by anchors or other means?
Are portable dockboards/birdge plates equipped with built-in handholds or fork loops/lugs?

General Storage (Section 13)

Is material stored as not to create a hazard? Explanation: Bags, containers, bundles etc. stored in tiers should be stacked, blocked, interlocked, and limited in height so they are stable and secure against sliding or collapse.
Are load limit signs posted in all storage areas except floor or slab on grade? Explanation: Maximum safe load limits of floors in pounds per square foot is to be posted in a conspicuously place. Load limits are not to be exceeded.