Introduction:
Forklift driving safety training matter, as 25% of industry accident occur due to forklift operation if we compare by the number only in USA, there are 758000+ numbers of industrial truck and operator, 7200+ injuries in 2020 and 78 worker died in 2020. That’s why Forklift Driving 101 safety training is very critical.
Forklift driving in Oil and Gas
While forklift are essential in for material shifting, movement, in this article you will walk through everything you need to know about forklift safety training specifically for oil and gas facilities, including real industry practice hazards, and compliance requirement.
Forklift driving in hazardous area
In hazardous area in oil and gas industry forklift must comply with regulation requirements:
- Use ATEX-Certified or explosion proof forklifts.
- Avoid Static discharge
- Follow permit to work system for forklift safe operation.
Real Industry Practice: Forklifts are often restricted from entering Zone 0 and Zone 1 areas unless specifically designed.
Common forklift hazards:
In this forklift driving safety training few of industry related hazards with real example are highlight below:
Load Instability:
During pipe yard operations, operator lifted unevenly stacked long pipes, causing the load to shift and fall, injured nearby worker.
Control: Load should be secure evenly, before any lifting operation. Operator and flag man ensure the load is secure.
Poor Visibility:
Forklift operator reversed without a spotter at road side in refinery area, and hit nearby pipe rack structure.
Control: without a spotter or flag man operator even operator can’t ignite the forklift, that’s why spotter signed is very necessary on PTW.
Uneven Surfaces
Example:
- Mud
- Sand
- Gravel
- Sloped surfaces
Control: Those uneven surfaces can lead in result stuck, or overturn of forklift, special metal plate are often use to make surface smooth forklift driving.
Human Interaction:
There was a sharp turn in warehouse, between material stack. Worker was passing the road at same time, operator sudden shock by seeing worker in front of forklift and apply sudden break. Fortunately no damage happen.
Control: At sharp end, reflection mirror should be install, Must be paint marking on forklift route and dedicated pathway for human to reduce human machine interaction incidents.
Key Components of Forklift Safety Training
Onsite forklift driving safety training must include:
Theoretical Training
- Forklift types and functions
- Load capacity and stability principles
- Hazard identification
- Site-specific safety rules
- Emergency procedures
Practical Training
- Safe starting and stopping
- Load lifting and stacking
- Driving on slopes
- Maneuvering in tight spaces
- Operating in hazardous zones
Site-Specific Training
- Understanding hazardous area classifications
- Emergency shutdown procedures
- Fire prevention practices
- Working near pipelines and tanks
Entering Forklift
An operator must ensure before entering in forklift:
- Complete your daily pre-inspection and fill check list.
- Always enter with three points of contact.
- Never jump out if the forklift is tipping over.
- Always check PTW and spotter before start of operation.
Daily Pre-Operation Inspection Checklist
An operator with PTW receiver or supervisor must inspect the forklift visually and physically by ensuring below and fill daily check list as per conditions
- Tires – Overall Condition of tires and air pressure.
- Break and Steering – Ensuring break by dry run and steering movement.
- Warning Devices – Warning lights including reverse light, horn with reverse alarm.
- Hydraulics – Check with hydraulics fuel and system.
- Fork and Mast: Inspect overall condition of fork and mast; Dry run test should be performing for forks.
- Cabin: Inspection of operator cabin, Seat, Seatbelts, Meter and AC.
- Fuel: Fuel level and battery level.
Note: No operation should be carrying out if any of above or any other inspection test fails and status on check list is not fit for operations.
Compliance with Safety Standards and Safe Working Practice:
In this forklift driving safety training, we bring some real time safe working practices and safety standards use in Oil and gas industry, compliance with those standards and safe working practices has some significant impact in reducing overall risk.
- Always obtained a PTW before any forklift operation which include hazards identification, hazards control and crew details and authorization
- Forklift should be third party inspected and valid certification and organization inspection sticker.
- Operator has valid forklift operation license from country licensing authority
- Operator pass the third party certification and operate only allowed forklift
- Never cross the safe working load limits
- Always use Spotter or flag man, they are trained and must well aware of routes and operation
- Always wear proper PPE, Helmet, Safety Boots, gloves and safety goggles
- Maintain safe speed and don’t cross speed limit
- Keep forks low while driving
- Never stand underneath or above fork in any situation. This is big safety violation.
- Always pay attention to surrounding.
- Stop operation during emergency or any un safe condition
Every organization has certain safe working practices and standards, high risk area must require a valid JSA and Risk Assessments, ensure compliance with safety standards for your own and other safety.
Unsafe Act that leads to an Incident
There are several unsafe acts in the consequences those act can lead to an incident a near miss or a major accident. In this forklift driving safety training we tried to give few examples from real industry
- Not fulfilling permit requirements.
- Operating without training
- Ignoring inspection checks
- Carrying passengers
- Driving with elevated loads
- Not wearing PPE
- Using forklift for unintended purposes
Handling Freight – Basic Safety
In this forklift driving safety training we have covered some basic safety practices for handling freight
- Slowly approach the load
- Tilt the mast and load toward the driver
- Load Should be lifted only a few inches of the ground
Unloading freight
- Make sure the resting destination is stable
- Stop and raise the load to required height
- Drive forward once the load in position
Freight operation in confined area
- Inspect the area to make sure it’s well – lit and ventilated
- Make sure dock boards or bridge plates are secure
Turning off the forklift
- Lower the forks to the floor
- Put the forklift in neutral
- Set the parking brake
- Remove the key from the ignition
Refueling
- Acid to water, Not water to acid
- Close the fuel line valve first when using LPG
- Always wear PPE according to facility safety policies
Conclusion
Forklift operations in the oil and gas industry are far more complex than in typical industrial environments. Without proper training, the risks can be severe and life-threatening.
A well-structured Forklift Driving Safety Training, ensures that operators are not only skilled but also aware of the unique hazards present in oil and gas facilities.