Materials Handling

1
Materials Handling

• MODULE 18

2
Materials Handling on Oil and Gas Sites

• What materials are handled?
• What machines are used to handle them?
• What precautions are taken to avoid accidents and
  injuries?

3
Regulations

• 29 CFR 1910 Subpart N
• 29 CFR 1926 Subparts H and N
• API RP 54, 4G, 9B
• ANSI B56.6 for forklifts
• Crane standards for derricks?
• RP 54 and general duty clause
• Look at application for each crane standard

4
Materials Handling and Storage

• 29 CFR 1910 SUBPART N

5
Organization of Subpart N

• 1910.176 - Handling materials - general
• 1910.177 - Servicing multi-piece and single piece
  rim wheels
• 1910.178 - Powered industrial trucks
• 1910.178 App A Stability of powered industrial
  trucks (non-mandatory)
• 1910.179 - Overhead and gantry cranes
• 1910.180 - Crawler locomotive and truck cranes
• 1910.181 - Derricks
• 1910.183 - Helicopters
• 1910.184 - Slings

6
1910.176 Handling materials - general

• Mechanical equipment safe clearances permanent
  passageways marked
• Housekeeping avoid tripping, fire, explosion,
  or pest harborage hazards
• Covers or guardrails for open pits, tanks, vats,
  ditches

7
1910.176 Handling materials - general

• Storage must not create a hazard Stable/secure
  against sliding or collapse

8
1910.177 Servicing multi-piece and single-piece
rim wheels

• Applies to large vehicles not pickups,
  automobiles, or vans
• Training
• Tire servicing equipment
• Wheel component acceptability
• Safe operating procedures

9
Powered Industrial Trucks

• 29 CFR 1910.178

10
1910.178 Powered industrial trucks

• Contains safety requirements relating to
• Fire protection
• Design
• Maintenance
• Use of fork trucks, tractors, platform lift
  trucks, motorized hand trucks, and other
  specialized industrial trucks powered by electric
  motors or internal combustion engines

11
1910.178 Powered industrial trucks

• ANSI B56.1 1969
• Marking indicating approval by testing laboratory
• No modifications that affect capacity and safe
  operation without manufacturers prior written
  approval
• Front-end attachments identified
• Markings maintained legible

12
1910.178(b) and (c)

• Designations for industrial trucks by fuel and
  safeguards against ignition source
• Designated locations where specific types of
  trucks may be used
• Table N-1

13
1910.178(e) Safety guards

• Overhead guards for High Lift Rider trucks if
  operations permit
• Vertical load backrest extension for types of
  loads that present hazards

14
1910.178(f) Fuel handling and storage

• Storing and handling of liquid fuels Follow NFPA
  No. 30-1969
• Storing and handling of LPG fuel Follow NFPA No.
  58-1969

15
1910.178(g) Changing and charging storage
batteries

• Battery charging installations located in areas
  designated for that purpose
• Facilities provided for
• Flushing and neutralizing spilled electrolyte,
• For fire protection,
• For protecting charging apparatus from damage by
  trucks, and
• For adequate ventilation for dispersal of fumes
  from gassing batteries

16
1910.178(g) Changing and charging storage
batteries

• Conveyor, overhead hoist, or equivalent provided
  for handling batteries
• Reinstalled batteries properly positioned and
  secured in the truck

17
1910.178(g) Changing and charging storage
batteries

• When charging batteries, acid poured into water
  not water poured into acid
• Trucks properly positioned and brake applied
  before attempting to change or charge batteries
• Care taken to assure that vent caps are
  functioning

18
1910.178(g) Changing and charging storage
batteries

• Smoking prohibited in the charging area
• Precautions taken to prevent open flames, sparks,
  or electric arcs in battery charging areas
• Tools and metallic objects kept away from the
  tops of batteries

19
1910.178(h) and (i)

• Auxiliary directional lighting on truck if
  lighting lt2 lumens per square foot
• Control carbon monoxide to levels in 1910.1000

20
1910.178(k) Trucks and railroad cars

• Brakes set and wheel chocks placed for highway
  trucks boarded with powered industrial trucks
• Positive protection to keeptrain cars from
  moving while loading or with dockboards/bridge
  plates
• Fixed jacks for uncoupled semitrailer during
  loading

21
1910.178(l) Operator training

• Ensure that before employee operates a powered
  industrial truck, operator has completed training
  and evaluation successfully
• Trainees may operate a powered industrial truck
  only
• Under direct supervision of persons with the
  knowledge, training, and experience to train
  operators and evaluate their competence and
• Where such operation does not endanger the
  trainee or other employees.

22
1910.178(l) Operator training

• Required
• Lecture or other formal instruction (computer,
  video tape, written)
• Practical training (demonstrations and exercises)
• Evaluation by trainer of operator performance in
  workplace
• Refresher training required after certain
  conditions in (4)

23
1910.178(l)(3) Training program content

• Truck-related training topics
• Operating instructions, warnings, and precautions
  
• Differences between the truck and the automobile
• Truck controls and instrumentation
• where they are located
• what they do
• how they work
• Engine or motor operation
• Steering and maneuvering
• Fork and attachment adaptation

24
1910.178(l)(3) Training program content

• Truck-related training topics
• Vehicle capacity
• Vehicle stability
• Any vehicle inspection and maintenance that the
  operator will be required to perform
• Refueling and/or charging and recharging of
  batteries
• Operating limitations
• Operating instructions, warnings, or precautions
  listed in the operator's manual

25
1910.178(l)(3) Training program content

• Workplace-related topics
• Surface conditions
• Composition of loads and load stability
• Load manipulation, stacking, and unstacking
• Pedestrian traffic in areas where the vehicle
  will be operated
• Ramps and other sloped surfaces that could affect
  the vehicle's stability

26
1910.178(l) Certification

• The certification shall include
• Name of the operator
• Date of the training
• Date of the evaluation, and
• Identity of the person(s)
  performing the training or evaluation
• Previous training does not need to be repeated if
  operator can operate safely

27
1910.178(m) Truck operations

• Trucks never driven up to anyone standing in
  front of a bench or other fixed object
• No one allowed to stand or pass under the
  elevated portion of any truck,
  whether loaded or empty
• Unauthorized personnel not permitted to ride on
  powered industrial trucks
• A safe place to ride provided where riding of
  trucks is authorized

28
1910.178(m) Truck operations

• Prohibit arms or legs from being placed between
  the uprights of the mast or outside the running
  lines of the truck
• When truck left unattended (25 ft. away or out of
  view)
• load engaging means fully lowered
• controls neutralized
• power shall be shut off
• brakes set

29
1910.178(m) Truck operations

• Maintain safe distance from edges of ramps or
  platforms while on any elevated location
• Never use trucks to open or close freight doors
• Trucks, trailers, and railroad cars Immobilize
  vehicles and check floors for breaks and weakness
  before driving on

30
1910.178(m) Truck operations

• Overhead guard as protection against falling
  objects
• Intended to offer protection from the impact of
  small packages, boxes, bagged material, etc.
• Not intended to withstand the impact of a falling
  capacity load

31
1910.178(n) Traveling

• Follow all traffic regulations, including
  authorized speed limits
• Maintain safe distance approximately three truck
  lengths from the truck ahead
• Keep truck under control at all times

32
1910.178(n) Traveling

• Never pass other trucks traveling in the same
  direction at intersections, blind spots, or other
  dangerous locations
• Slow down and sound horn at cross aisles and
  other locations where vision is obstructed
• If the load being carried obstructs forward view,
  travel with the load trailing

33
1910.178(n) Traveling

• Ascending or descending grades gt10 drive loaded
  trucks with the load upgrade
• On all grades the load and load engaging means
  tilted back if applicable, and raised only as far
  as necessary to clear the road surface

34
Overhead and Gantry Cranes

• 29 CFR 1910.179

35
1910.179(b) General Requirements

• Application cranes with trolleys and other
  characteristics similar to gantry cranes
• ANSI B30.2.0-1967
• Rated load marking on each side and legible from
  the floor
• Operated by designated personnel only

36
Organization of Standard

1. Cabs access, controls, location
2. Footwalks and ladders location, construction,
   walking/working surfaces
3. Stops, bumpers, rail sweeps, and guards
4. Brakes
5. Electric equipment, including controllers

37
Organization of Standard

1. Hoisting equipment sheaves, ropes, equalizers,
   hooks
2. Warning device
3. Inspection frequent and periodic
4. Testing operational and load
5. Maintenance
6. Rope inspection

38
Organization of Standard

• Handling the load
• Size
• Attaching the load
• Moving the load
• Hoist limit switch
• Other requirements ladders, cabs, fire
  extinguishers

39
Crawler, Locomotive, and Truck Cranes

• 29 CFR 1910.180

40
1910.180(b) General Requirements

• Application
• Crawler cranes, locomotive cranes, wheel mounted
  cranes, used as lifting cranes
• Both truck and self-propelled wheel type
• Powered by internal combustion engines or
  electric motors
• Utilize drums and ropes
• ANSI B30.5-1968
• Operated by designated personnel only

41
Organization of Standard

1. Load ratings
2. Inspection classification
3. Testing
4. Maintenance procedure General
5. Rope inspection
6. Handling the load
7. Other requirements
8. Operations near overhead lines

42
Derricks

• 29 CFR 1910.181

43
1910.181(b) General Requirements

• Application
• any modification of these types which retain
  their fundamental features, except for floating
  derricks
• ANSI B30.6-1969
• Operated by designated personnel only

44
Organization of Standard

1. Load ratings permanent and nonpermanent
2. Inspection
3. Testing
4. Maintenance
5. Rope inspection
6. Operations of derricks
7. Handling the load
8. Other requirements

45
Slings

• 29 CFR 1910.184

46
Application

• Used for hoisting of material
• Alloy steel chain
• Wire rope
• Metal mesh
• Natural or synthetic fiber rope
• Synthetic web
• Illustrations in (b)

47
(c) Safe operating practices

1. Never use damaged / defective slings
2. Never shorten slings with makeshift devices
3. Never use kinked sling legs
4. Never load slings in excess of rated capacities
5. Balance loads in basket hitches to prevent
   slippage.

48
(c) Safe operating practices

1. Attach slings securely to loads.
2. Pad / protect slings from sharp edges.
3. Keep suspended loads clear of obstructions
4. Keep employees clear of loads to be lifted and
   suspended loads.

49
(c) Safe operating practices

1. Never place hands or fingers between sling and
   load while sling is being tightened.
2. Shock loading is prohibited take up the slack
   in the sling slowly.
3. Never pull a sling out from under a load while
   the load rests on it.

50
Organization of Standard

1. Inspections each day before use and during use
2. Alloy steel chain slings
3. Wire rope slings
4. Metal mesh slings

51
Construction Standards

• 29 CFR 1926 Subparts H and N

52
Applicability of Construction Standards in 29 CFR
1926

• Subpart H Materials Handling, Storage, Use, and
  Disposal
• Subpart N Cranes, Derricks, Hoists, Elevators,
  and Conveyors
• Do construction standards apply
• To a derrick during drilling operations?
• To a crane setting up equipment at a site?

53
Hazards Standards for Oil Gas

• API RP 54, RP4G, RP9B