HSE-SAF-STD-00-0026

SAFETY
Rev. 3

POWERED INDUSTRIAL TRUCK (PIT) 22-Aug-2016

STANDARD Page 1 of 9

TABLE OF CONTENTS

1. INTRODUCTION .......................................................................................................... 2

2. SCOPE & PURPOSE ................................................................................................... 2

3. DEFINITIONS ............................................................................................................... 2

4. POWERED INDUSTRIAL TRUCK (PIT) STANDARD ................................................. 3

5. RESPONSIBILITIES .................................................................................................... 8

6. REFERENCES ............................................................................................................. 8

7. ATTACHMENTS .......................................................................................................... 9

8. APPENDICES .............................................................................................................. 9

9. REVISION HISTORY.................................................................................................... 9

Rev. Issue Date Amendment Description Prepared By Reviewed By Approved By

Carl Poldrack/
Arantelo D
Roehl
Abreu/
 Periodic Revision Bartolome/
Kosay B Noori/
Abdulla S Al-
 The refresher training requirements added for Noberto B
Khulaifi/
3 22-Aug-16 employees and contractors (sec. 4.5 (ii) & (iii)) Ranjeet K Maity Ayson/
Abdulla S Al-
 The ‘Site Vehicle and Traffic Safety Standard’ Firozkhan S
Zoubi/
is added as a reference (sec. 4.4. (vi) & 6) Pathan/
Dirk Perrin/
Singaravelu
Abdulaziz Y
Ekambaram/
Al-Motawa
Next Scheduled Periodic Review: August/2019

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1. INTRODUCTION

Powered Industrial Trucks (PITs) are used at Q-Chem manufacturing facilities for various
maintenance and operational requirements.
Thousands of injuries and numerous deaths occur every year because of incidents involving
the use of PITs. Most of these incidents are as a result of lack of training, improper use of
equipments and poor maintenance of the trucks. This Standard reflects the OSHA Standard
for the safe operation of PITs.

2. SCOPE & PURPOSE

This document provides basic standards and guidelines for procurement, use and training of
operators of PITs at Q-Chem manufacturing facilities in Mesaieed and Ras Laffan.
The purpose is to ensure that these PITs meet OSHA standard and the affected personnel are
adequately trained to use them. OSHA standards are published as Regulations under
Standards – Powered Industrial Trucks: 29 CFR 1910.178.
PITs which are included in this standard are:
 Fork Lift Trucks
 Reach Stackers (Container Handling Hydraulic Cranes)
 Yard Tractors (‘Yard Dogs’)
 Skid Steering Loaders (‘Bobcats’)
PITs specifically excluded from this standard are:
 Man lifts (Aerial Platforms)
 Cranes (except Reach Stackers)
 Pickup Trucks/vans or similar vehicles.

3. DEFINITIONS

 Authorized Maintenance Personnel: Q-Chem/RLOC personnel, base load contractors,

third party maintenance contractors or vendors’ technicians who have the reason to
properly carry out maintenance activities on the trucks.
 Authorized Operators: Q-Chem/RLOC personnel or contractors who have been
authorized and certified to operate PIT.
 Classified Area: A defined or separated area due to the possibility or probability of
experiencing the presence of flammable liquids, gases, combustible dusts, or readily
ignitable fibres or flying particles. In Article 500 of the National Electrical Code (NEC),
hazardous classifications are divided into three classes (class I, II, and III) and special
electrical classified equipment is built into the design appropriately.
 Competent Person: A person with the knowledge, training and experience to train PIT
operators and evaluate their competence.
 DSR: Designated Site Representative - A person serving as the focal point for facility
contact and interaction with the contractor. This person will be a Q-Chem/RLOC employee
or a contractor over whom Q-Chem/RLOC has direct control. It will not be a representative
from the same contractor doing the work.
 Owner: The Superintendent or his/her designate of the area in which the PIT is normally
used.
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 Powered Industrial Truck: A fork lift truck, reach stacker, tractor, motorized hand truck
or similar specialized industrial truck powered by electric motor or internal combustion
engine.
 e-SOMS: Electronic Shift Operations Management System
 SME : Subject Matter Expert

4. POWERED INDUSTRIAL TRUCK (PIT) STANDARD

4.1. Procurement

i. All PITs purchased/leased for Q-Chem/RLOC must meet a recognised international

standard and registered with State of Qatar. All PITs are to be provided with any
necessary test certificates and a copy of the operator’s/maintenance manual.
ii. All end users of Q-Chem/RLOC owned PITs, are to ensure that the truck is registered with
Maintenance Department prior to use.

4.2. Care and Maintenance

i. All the trucks shall be maintained in accordance with the vendor’s maintenance schedule.
Refer to MC-GEN-PRO-00-0003 (Vehicle Maintenance) for PIT periodic inspection
checklist and retain the completed checklists as per the Records and Information
Retention Schedule (QC-IMT-SHD-00-0001).
ii. PIT shall be inspected by the operator before each shift or day’s use with a daily checklist
given in the attachment specific to the type of PIT and retained as per Records and
Information Retention Schedule.

NOTE 1
Logistics Section has a dedicated/custom made Inspection Checklists for
Fork lift/Reach Stacker/Yard Tractor operation which are referred in section
6. The points in the general checklist are all critical.

iii. e-SOMS hand held can be used in place of hard copy check list. But all the applicable
points in the checklist to be covered.
iv. Any deficiency identified during the inspection process shall be notified to the respective
supervisor/DSR for further follow-up. The PIT operator shall visibly post the “Do Not
Operate” information tag with the details of the deficiency in the PIT. Based on the SME
evaluation, the PIT shall be taken out of service for necessary action.
v. No repairs shall be made to trucks in classified areas.
vi. Trucks in need of repair to the electrical system shall have the battery disconnected prior
to such repairs.
vii. Repair shall be done only by the authorized maintenance personnel.
viii. Any parts requiring replacement shall be replaced only by parts equivalent to the original
design.
ix. Trucks shall not be modified from their original condition without written approval from the
manufacturer or his agent.
x. Trucks shall be kept in a clean condition free of lint, excess oil, and grease. Non-
combustible agents should be used for cleaning trucks.

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4.3. PIT Safety and Operations

i. Only personnel, who are trained, authorized and certified, can operate the PIT in Q-Chem
manufacturing facilities. The PIT operators shall have valid Qatar Driving License specific
to the type of PIT they operate.
ii. PITs shall have seat belt fitted. It is to be worn by the PIT operator any time the PIT is in
use.
iii. Operators shall pay particular attention to the operating environment, including other
persons, and fixed or movable objects in the vicinity, and shall safeguard pedestrians at
all times.
iv. PIT shall not be driven towards anyone standing in front (line of fire).
v. PITs shall have legible name plate and markings.
vi. PIT shall never be overloaded. When attachments are used on forklift, the combined
weight of the load and attachment shall not exceed the lifting capacity of the forklift.
vii. No person shall be allowed to stand or pass under the elevated portion of any PIT,
whether loaded or empty.
viii. Never permit passenger to ride on the PIT unless it is designed to carry passengers.
ix. Personnel should not place arms or legs between the uprights of the mast or outside the
running lines of the PIT.
x. When a PIT is left unattended, the load engaging means is to be in the fully lowered
position, power is to be shut off and brakes set. Wheels are to be chocked if parked on an
incline.

NOTE 2
A PIT is considered as unattended if the PIT is ON, but not in operator's
view or the operator is 25 ft or more away from the vehicle even the PIT
remains in his/her view.

xi. A safe distance is to be maintained from the edge of ramps, platforms or dock. Trucks
shall not be used for opening or closing freight doors except where authorized and with
use of special adaptors.
xii. Brakes shall be set to prevent movement of trucks and trailers while loading or unloading.
Fixed jacks are necessary to support a semitrailer during loading of PE products on the
stuffing bay.
xiii. The flooring of trucks and trailers shall be checked for breaks and weakness before they
are driven onto.
xiv. Operators of PITs are to ensure sufficient headroom under overhead installations such as
lights, pipes, sprinkler systems etc.
xv. As applicable, use spotter when the area is congested or area is limited for maneuvering
etc.,
xvi. Only PITs fitted with an operator cabin or overhead guard to prevent the operator being
injured by falling objects shall be used.
xvii. Wherever necessary a load backrest shall be used to minimize the possibility of the load
falling backwards.

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xviii. Fire aisles, access to stairways, and fire equipment access shall not be blocked at any
time.
xix. All traffic regulations are to be observed including Plant speed limits. The PIT shall be
driven under control at all times and in a manner whereby it may be halted safely in the
event of an obstruction or unexpected traffic occurrence.
xx. A safe distance shall be maintained approximately three truck lengths from the truck
ahead.
xxi. Overtaking is not allowed inside the Plant.
xxii. PIT should cross the crane rail tracks diagonally.
xxiii. Drivers must look in the direction of travel while driving PIT and keep a clear view of the
path of travel. If the PIT is carrying a load high enough to obstruct forward vision, the PIT
shall travel backwards.
xxiv. The driver shall be required to slow down and sound the horn at cross aisles and other
locations where vision is obstructed.
xxv. Any grades shall be ascended or descended slowly. When ascending or descending
grades in excess of 10 percent, loaded trucks shall be driven with the load upgrade.
Turns are not to be made on a grade. On grades the load and load engaging means shall
be tilted back from the direction of travel.
xxvi. Stunt driving or horseplay is not permitted.
xxvii. Dock boards or bridge plates are to be properly secured before being driven over. Dock
boards or bridge plates shall be driven over carefully and their rated capacity is never to
be exceeded.
xxviii. Running over loose objects is to be avoided.
xxix. While negotiating turns speed shall be reduced to that appropriate to negotiate the turn
correctly. Except when maneuvering at a slow speed, the hand steering wheel shall be
turned at a moderate, even, rate.
xxx. Operators are to slow down on wet or slippery surfaces. Under all travel conditions the
truck shall be operated at a speed that will permit it to be brought to a stop in a safe
manner.
xxxi. Only stable or safely arranged loads are to be handled. Additional caution shall be
exercised when handling off-center or irregular loads which cannot be centered.
xxxii. Trucks with attachments (e.g. push/pull units) shall be operated as partially loaded trucks.
(Refer to load chart)
xxxiii. Forks shall be spread under the load as far as possible; the mast shall be tilted backwards
to stabilize the load. Always travel with the load as low as possible while maintaining
good floor clearance. Keeping the load low helps maintain the stability of the forklift.
xxxiv. Extreme care should be taken while tilting the load forward or backward.
a) An elevated load is not to be tilted forward except when the load is in deposit position
over a rack or stack.
b) Tilting the load forward is also allowed to pick up a load and when engaging the slip
sheet retainer of push pull unit.
c) Backward tilt is allowed to stabilize the load while stacking or tiering.
xxxv. If the truck is found to be in need of repair it shall be taken out of service and notified to
the respective supervisor/DSR for further follow-up. Operators are not to attempt to repair
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trucks. The PIT operator shall visibly post the “Do Not Operate” information tag with the
details of the deficiency in the PIT. Based on the SME evaluation, the PIT shall be taken
out of service or allowed with documented justification.
xxxvi. Fuel or LPG tanks are not to be filled while the engine is running.
xxxvii. No truck shall be operated with a leak in the fuel system.
xxxviii. Any vehicle that emits hazardous sparks or flames from the exhaust system shall
immediately be removed from service and not returned to service until the cause for the
emission of such sparks and flames has been eliminated.
xxxix. Battery charging installations shall be located in areas designated for that purpose.
Appropriate precautions to be taken for battery operated PITs to prevent electrolyte
spillage/battery explosion.
xl. Battery charging facility shall have provision for flushing and neutralizing spilled electrolyte
and shall have adequate ventilation for dispersal of fumes from gassing batteries as part
of fire protection. The operator should check the availability of safety shower/eye washer
by testing the flow prior to battery charging operation. Charging apparatus shall be
protected from accidental damage by moving vehicles.
xli. Trucks shall be properly positioned and brake applied before attempting to change or
charge batteries. Only trained and authorized personnel shall change or charge batteries.
xlii. Care shall be taken to assure that vent caps are functioning. The battery (or compartment)
cover(s) shall be open to dissipate heat.
xliii. Smoking shall be prohibited in the charging area.
xliv. Precautions shall be taken to prevent open flames, sparks, or electric arcs in battery
charging areas.
xlv. Tools and other metallic objects shall be kept away from the top of uncovered batteries to
prevent the personnel from shorting on cell connectors or terminals.
xlvi. Charging area should have adequate lighting.
xlvii. Forklifts/Bobcat owned and operated by contractors:
a) There are situations when the contractor will use their forklift/bobcat during the
maintenance and projects inside the facility. The DSR is responsible for forklift/bobcat
inspection and approval before its usage. The DSR should use the forklift/bobcat initial
inspection form and document the inspection/approval. This form shall be retained in
the forklift/bobcat. The DSR shall provide inspection sticker on the forklift/bobcat.
b) DSR should verify the contract employee training certification and its validity.
c) DSR should coordinate with support services supervisor/engineer or his designee to
approve the equipment’s 3rd party certificate.
d) Contractor should use the facilities forklift/bobcat daily inspection checklist as long as
the forklift/bobcat operated inside the facility. DSR has to give these forms to
respective contractors.
e) If there is any defect identified, the contractor shall place “Do Not Operate Tag” and
communicate it to DSR. DSR shall not permit the forklift/bobcat usage until it is
repaired.

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4.4. Training

i. Trainees may only operate a PIT:

a) Under the direct supervision of a person with the knowledge, training and experience to
train an operator and evaluate his competence; and
b) Where such training does not endanger the trainee or other employees.
ii. Training shall consist of a combination of formal instruction (Lecture, discussion, video
and printed material), practical training (demonstrations by trainer and practical exercises
performed by the trainee) and evaluation of the operator’s performance. Trainees will be
certified after evaluation.
iii. All operator training and evaluation shall be performed by the competent personnel. A
record of training shall be kept with the employees training record in the Training Section
iv. The qualified operators shall be issued with an identification card with below information:
a) Name / photo of the authorised operator
b) Date of certification/validity of the certification
c) Name of the trainer/evaluator
d) Type/class of PIT on which the operator is certified

NOTE 3
Refer to Appendix I for different classes of Powered Industrial Truck. A
need to drive different type/class of PIT will require training on that
particular PIT.

v. Authorized operators from non-base load contractors or those mobilized during special
projects (e.g. planned maintenance or turnaround) shall be certified through approved
third party training. DSR shall ensure that these operators are in possession of a valid
certificate and license.
vi. Personnel who operate PITs in Q-Chem manufacturing facilities shall have a valid Qatar
driving license, specific to the type of PIT as required by the Site Vehicle and Traffic
Safety Standard (HSE-SAF-STD-00-0044).
vii. PIT Operator shall have a valid third party certification and/or Q-Chem/RLOC Training
Section certification specific to the type of PIT.

4.5. Refresher Training

i. Refresher training shall be carried out when:

a) The operator has been observed to operate the vehicle in an unsafe manner.
b) The operator has been involved in an incident or near miss.
c) The operator has received an evaluation that reveals that the operator is not operating
the truck safely.
d) The operator is assigned to drive a different type of truck.
e) A condition in the workplace changes in a way that could affect the safe operation of
the truck.

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ii. Refresher training to the employees and Base load Contractors shall be performed by the
competent personnel either by Training Coach, Unit Supervisor, DSR or third party
certificate. A record of training shall be kept with the employees training record in the
Training Section.
iii. Refresher training to the Non-Base load Contractors shall be provided by their company.
DSR shall verify the training records and validity.

4.6. Evaluation

i. Each PIT Operator (Employee or Base load Contractor) who has been certified by Q-
Chem/RLOC Training Section must have his/her performance evaluated every 3 years by
a competent person using the PIT Observation Form (HSE-SAF-SFM-00-0049).

5. RESPONSIBILITIES

5.1. End user

i. PIT owners are responsible for the day to day care and safe operation of the vehicles.
This includes daily inspections and scheduling routine maintenance activities with
maintenance as well as the prompt reporting of any defects.
5.2. Maintenance Department
i. Responsible for the general oversight and supervision of all vehicle maintenance
activities.
5.3. Supervisors
i. Identify and arrange refresher training in the event of occurrences under Para 4.5.
ii. Ensure PIT daily inspections are carried out. If any deficiencies identified, evaluate the
impact and approve/disapprove the PIT usage and follow up to correct the deficiency.
5.4. Contracts Department
i. As applicable, ensure that the requirement of third party certification of PIT Operators is
included in the contract.
5.5. Designated Site Representative
i. Facilitate the inspection of PIT by Q-Chem/RLOC maintenance and ensure the operators
are in possession of a valid training certificate issued by third party.
5.6. Training Section
i. Ensure that the PIT operator has a valid Qatar driving license prior to conducting in-house
PIT training.
ii. Issue the PIT compliance card to the trained operators.

6. REFERENCES

6.1. OSHA Standard 29 CFR 1910.178

6.2. Vehicle Maintenance Procedure MC-GEN-PRO-00-0003
6.3. Site Vehicle and Traffic Safety Standard HSE-SAF-STD-00-0044
6.4. Fork Lift Daily Inspection Checklist (Logistics) PD-LGN-SFM-00-0037
6.5. Reach Stacker Daily Inspection Checklist PD-LGD-SFM-07-0008

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6.6. Yard Tractor Daily Inspection Checklist PD-LGD-SFM-07-0009

6.7. Introduction to Powered Industrial Trucks Training Presentation HSE-SAF-PPT-00-0103
6.8. Introduction to Powered Industrial Trucks – Refresher Training HSE-SAF-CBT-00-0043
6.9. Spotter an Individual Trained to Look Presentation AD-TRN-PPT-00-0045

7. ATTACHMENTS

7.1. PIT Operator Observation Form - HSE-SAF-SFM-00-0049

7.2. Skid Steering Loaders (Bobcat) Initial Inspection Checklist- HSE-SAF-SFM-00-0116
7.3. Skid Steering Loaders (Bobcat) Daily Inspection Checklist- HSE-SAF-SFM-00-0117
7.4. Forklift Daily Inspection Checklist (General) - HSE-SAF-SFM-00-0118
7.5. Forklift Initial Inspection Checklist - HSE-SAF-SFM-00-0119

8. APPENDICES

8.1. Appendix I : Classification of Powered Industrial Trucks

The US Industrial Truck Association has classified PITs into 7 classes:

CLASS I: Electric motor rider trucks
CLASS II: Electric motor narrow aisle
CLASS III: Electric Motor Hand trucks or hand/rider trucks
CLASS IV: Internal Combustion Engine trucks (solid/cushion tyres)
CLASS V: Internal combustion engine trucks (pneumatic tyres)
CLASS VI: Electric and internal combustion engine tractors
CLASS VII: Rough terrain forklift trucks

9. REVISION HISTORY

Rev. Issue Date Amendment Description Prepared By Reviewed By Approved By

 Included RLOC also in the scope of this
standard.
 Section 4.3 (PIT safety and operations)
updated with OSHA requirement.
 Added control on contractors PITs inside Q-
Venkata S Roehl Carl
2 18-Aug-13 Chem manufacturing facilities.
Chandra Bartolome Poldrack
 Developed Forklift/Bobcat/Reach
Stacker/Yard Tractor daily inspection
checklists and Forklift/Bobcat Initial inspection
checklists and linked in this standard.
 Section 4.4 & 4.5 updated.
 Added definition of Authorized Operator
 Scope amended to include all forklift
1 15-Jan-10 operations including those during Faiz Ahmed Ron Turley Jarvis Olsen
project/turnaround
 Included the requirement of training card

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