12.5 - ES-MECH-012.pdf

MINOR CHANGE REQUEST FORM

MCR NO. ES-MECH-012,R2-002

(e.g., MCR-ENG-021,R0-001)

The Minor Change Request (MCR) Form is to be used to process Minor, or in some necessary cases, Urgent or Temporary changes to PPPL Lab-wide procedures). The MCR should be used when changes are:

1) minor and do not warrant further SME review;

2) urgent and cannot wait the 2-4 week period for further SME review; or

3) temporary, to revert to original state by a given expiration date (must be within 6 months).

For questions about definitions of “minor,” “urgent,” and “temporary” changes, please review Lab-wide Procedure GEN-001, Development, Review, and Approval of Lab-wide Documents.

Person Requesting Change: M. Viola Phone Ext: 3655

Department Name: Engineering

Document Number: ES-MECH-12 Revision No.:_2_

Document Title: Manlifts

Reason for change:

Update “Service Report” forms in chapters to include a third requirement check box: “All product recalls and safety improvements have been installed.” ; Add list of chapters to Introduction

Change description: (Summarize and attach changed pages, with changes clearly indicated) Added “All product recalls and safety improvements have been installed” as a check box in each “Service Report” ; added list of chapters to introduction, section 1.

1. Does this change significantly alter the intent or scope of the document? YES: NO: X

2. Does this change significantly impact ES&H? YES: NO: X

If 1 or 2 is YES, explain why the changes should not be submitted as a revision:

3. Place a check mark next to the appropriate type of change request:

• Minor change? __________

• Urgent change? (revision must follow within 2 weeks) _________

• Temporary change? _________ If “temporary change” is checked, provide expiration date, allowing document to revert to original state (must be within 6 months): ______________

Management System Owner/Designee Approval Date

Head, PPRM/designee Date

Release/Effective date of this MCR: 11/30/18

Printed copies of this document are considered UNCONTROLLED / Information Only copies. The official document is at http://bp.pppl.gov/PPPL_docs.shtml

The Project, Performance, and Requirements Management Office maintains the signed originals.

PRINCETON PLASMA

PHYSICS LABORATORY

ENGINEERING STANDARD No. ES-MECH-012 Rev. 2

Subject:

Manlifts

Effective Date:

February 12, 2014

Initiated:

Manlift Manager

Supersedes:

Rev 1 May 31, 2013

Approved:

Head, Engineering

Chapter 1 Introduction

MCR-ES-MECH-012,R2-002

1.0 SCOPE/APPLICABILITY

This Engineer Standard covers the requirements for the safe operation of powered and manually operated manlifts while on the PPPL site, as well as equipment inspection, testing, maintenance, procurement and the training of operators for this type of equipment. Only qualified operators shall operate manlifts at PPPL. This chapter does not cover ladders, ladder stands or firefighting equipment. This standard applies to all workers at PPPL including PPPL employees, subcontractors, visitors and students.

2.0 INTRODUCTION

The use of specialized equipment to raise men, tools and materials to a position to perform work at elevation involves hazards having potential consequences ranging from minor injuries and minor property damage, to fatalities and major property losses. This standard will address the reduction of these hazards to risk levels that are acceptable through the use of defined controls such as the proper design, periodic inspection, maintenance, and use of mechanical devices; care and common sense; proper training and supervision; and the careful adherence to approved work and safety procedures.

3.0 REFERENCES

OSHA 29 CFR 1910 Occupational Safety and Health Standards OSHA 29 CFR 1926 Safety and health Regulations for Construction ESH 5008 PPPL Safety Manual ANSI SIA A92.2 2009 American National Standard for Vehicle-Mounted Elevating and Rotating Aerial Devices ANSI SIA A92-3 2006 American National Standard for Manually Propelled Elevating Aerial Platforms ANSI SIA A92-5 2006 American National Standard Boom-Supported Elevating Work Platforms

ANSI SIA A92-6 2006 Self-Propelled Elevating Work Platforms ANSI/NFPA 30 Flammable and Combustible Liquids Code ANSI/NFPA 505 Fire Safety Standard for Powered Industrial Trucks Manufacturer’s Operating Manuals PPPL Procedure ESH-001

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ENGINEERING STANDARD No. ES-MECH-012 Rev. 1

Chapter 1 Introduction

4.0. CHAPTERS

1.0 Introduction

2.0 Aerial Lifts

3.0 Scissor Lifts

4.0 Truck Mounted Aerial Lifts

5.0 Procurement

6.0 Definitions

MCR-ES-MECH-012,R2-002

MCR-ES-MECH-012,R2-002

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ENGINEERING STANDARD No. ES-MECH-012 Rev. 2

Chapter 2 Aerial Lifts

MCR-ES-MECH-012,R2-002

1.0 INTRODUCTION

For purposes of this Engineering Standard, all boom supported elevated platforms shall be referred to as aerial lifts. There are two types of aerial lifts in use at PPPL, the telescoping boom and the articulated boom. This chapter will cover both types of lifts. Operators must be qualified on the machine they are using.

For all electrical work requiring the use of aerial lifts, the requirements for aerial lifts and aerial work found in OSHA 1910.269 shall apply.

2.0 TRAINING

2.1 TRAINING REQUIREMENTS

Training shall consist of a combination of documented instruction (e.g., lecture, discussion, interactive computer learning, video, and/or written material), practical training (demonstrations performed by the Instructor and practical exercises performed by the trainee), and evaluation of the operator's performance in the workplace.

A. Personnel who have not been trained to operate aerial lifts may operate an aerial lift for the purposes of training only, and only under the direct supervision of the Instructor. This training should be conducted in an area away from other vehicles, obstacles, and pedestrians.

B. All operator training and evaluation shall be conducted by persons who have the knowledge, training, and experience to train operators and evaluate their competence. Instructor qualifications will be evaluated and documented by Human Resources per TR-005

C. The following topics will be covered in the training program of aerial lifts.

i. Operating instructions, warnings, and precautions;

ii. Vehicle controls and instrumentation: where they are located, what they do, and how they work;

iii. Safety Systems, including interlocks if any, and how they work;

iv. Engine or motor operation;

v. Responsibilities associated with problems or malfunctions affecting the operation of the lift;

vi. Work place inspection;

vii. Steering and maneuvering;

viii. Visibility (including restrictions due to loading);

ix. Raising, lowering and positioning of the platform for work;

x. Vehicle capacity;

xi. Vehicle stability;

xii. Any vehicle inspections and maintenance that the operator will be required to perform;

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ENGINEERING STANDARD No. ES-MECH-012 Rev. 2

Chapter 2 Aerial Lifts

MCR-ES-MECH-012,R2-002

2.1 TRAINING REQUIREMENTS (continued)

xiii. Fueling and/or battery recharging;

xiv. Operating limitations;

xv. Any other operating instructions, warnings, or precautions listed in the operator's manual for aerial lifts;

xvi. Tagout procedures per PPPL Procedure ESH-001;

xvii. Ramps and other sloped surfaces that could affect the equipment's stability;

xviii. LPG tank handling and safety issues.

D. The trainee operator shall have sufficient actual operation time under the direction of a qualified instructor to demonstrate proficiency in actual operation of the lift the operator is qualifying for.

E. Refresher training in relevant topics shall be provided to the operator when:

i. Every three years, including an evaluation of the operator’s performance;

ii. The operator has been observed to operate the equipment in an unsafe manner;

iii. The operator has been involved in an accident or near-miss incident;

iv. The operator has received an evaluation that reveals that the operator is not operating the aerial lift safely;

v. A condition in the workplace changes in a manner that could affect safe operation of the manlift.

F. Human Resources shall document that each operator has been trained and evaluated by a

Qualified Person as required by this Chapter. This qualification documentation shall include the name of the operator, indications of the Operator’s performance, the date of the training, or evaluation, and the identity of the person(s) performing the training or evaluation.

G. It is the responsibility of the supervisor to assure the Operator maintains the ability to operate the aerial lift during the 3 years of the qualification.

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ENGINEERING STANDARD No. ES-MECH-012 Rev. 2

Chapter 2 Aerial Lifts

MCR-ES-MECH-012,R2-002

2.2 TRAINING AND QUALIFICATION

In order to qualify as an aerial lift operator, the employee must successfully complete the training. The following requirements must be met:

Training Testing Renewal

Aerial Lift

Documented Written Every 3 Years

Instruction

Aerial Lift OJT Practical Every 3 Years

Aerial Lift Operator

Prerequisite Valid Driver’s License

Documented

Instruction* and

Testing

Aerial Lift Instruction, Written Test

Fall Protection Yes

Initial OJT and

Test Aerial Lift

3 Year

Requalification OJT and Written Test

* (e.g., lecture, discussion, interactive computer learning, video, written material).

Supervisors are responsible to assure that aerial lift operators maintain proficiency in the operation of the aerial lifts. Failure to maintain this proficiency will require the operator to retake the Practical Operations test.

2.3 TRAINING PROCEDURES

A. INITIAL TRAINING AND QUALIFICATION RESPONSIBILITIES

This section details the training and qualification requirements for aerial lift operators.

Qualified personnel or trainees shall be at least 18 years old, be able to read and understand the posted warning labels on the aerial lift and be able to understand the

Instructor.

Responsibility Action

Candidate's Supervisor or Manager

1. Requests training and qualification of personnel by contacting Human Resources.

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ENGINEERING STANDARD No. ES-MECH-012 Rev. 2

Chapter 2 Aerial Lifts

MCR-ES-MECH-012,R2-002

Human Resources 2. Select a qualified instructor to provide classroom training, practical training, and required tests, as applicable.

[Courses are approved PPPL courses or outside training approved by Manlift Manager.]

3. Schedule training and make all necessary logistical arrangements for the training.

4. Notify the candidate(s) of scheduled training and arranges for practical training, as necessary, verifies that candidate has a valid driver’s license.

Candidate 5. Attend the scheduled training course, or arranges to challenge any required training and tests through Human

Resources.

Qualified Instructor 6. Provide the appropriate training and testing. If manlift qualification is requested, the candidate is evaluated on each type of manlift to be used and the instructor documents the training on a Performance Evaluation

Checklist (see examples in Section 5.0 and Section 6.0).

Signs evaluation.

Human Resources 7. Prepare and maintain a qualification package for each successful candidate.

8. Prepare a PPPL Qualification Card with the appropriate qualification and expiration date entered on the qualification card. PPPL qualifications are valid for a period not to exceed three (3) years from the date of the practical or written test, whichever date is earliest.

9. Sign the PPPL Qualification Card for Manlift Operators.

10. Copy the completed card (both sides) for file, and distributes the card to the individual.

11. Maintain training and qualification records.

12. Monitor due dates and notifies the individual's manager or supervisor of actions needed to maintain or renew qualifications.

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ENGINEERING STANDARD No. ES-MECH-012 Rev. 2

Chapter 2 Aerial Lifts

B. CONTINUING TRAINING AND QUALIFICATION RESPONSIBILITIES

This section outlines the continuing (ongoing) training and qualification requirements for the aerial lift Qualifications listed in Training and Qualifications Requirements, Sections

2.2.

Human Resources 1. Notify the individual's supervisor or manager of continuing training and qualification requirements that require completion.

NOTE: Initial qualifications are issued for an effective period not to exceed three (3) years, unless otherwise specified or revoked, at which time requalification is required. If it is determined at any time that the capabilities of an individual are not in accordance with the qualifications specified for that job, that individual shall be removed from that job. Such removals shall be handled on a case-by-case basis by the PPPL Manlift Manager and the applicable supervisor.

Individual's

Supervisor and

Manager

2. Notify the individual of these continuing training and qualification requirements (such as medical examinations).

Human Resources 3. Arrange for refresher training and required tests for applicable qualifications.

4. Schedule On the Job Training (OJT) and make all necessary logistical arrangements for Manlift Operator qualifications.

5. Notify the individual of scheduled practical training.

Individual/

Candidate

6. Complete refresher training and challenge tests through

Human Resources. Note: Written tests must be current in order to renew Manlift Operator OJT.

Qualified

Instructor

7. Provide the OJT and evaluation for Manlift Operator qualifications and documents it on a Performance

Evaluation Checklist (Section 5.0 and Section 6.0).

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ENGINEERING STANDARD No. ES-MECH-012 Rev. 2

Chapter 2 Aerial Lifts

MCR-ES-MECH-012,R2-002

B. CONTINUING TRAINING AND QUALIFICATION RESPONSIBILITIES

(continued)

Human Resources 8. Prepare a PPPL Qualification Card with the appropriate qualifications and expiration date entered on the card.

PPPL qualifications are valid for a period not to exceed three (3) years from the date of the practical or written test, whichever date is earliest.

9. Sign the PPPL Qualification Card for Manlift Operators.

10. Copy the completed card (both sides) for file, and distribute the card to the individual.

11. Maintain training and qualification records.

12. Monitor due dates and notify the individual's manager or supervisor of actions needed to maintain or renew

C. PERFORMANCE EVALUATIONS

1. Performance evaluations are based on the performance items listed in the Aerial Lift

Performance Evaluation Checklist by a Qualified Person.

2. No numerical value is assigned to operational evaluations. The candidate's demonstrations are evaluated by the examiner as "satisfactory" or "unsatisfactory" based upon the following criteria:

i. The individual exhibits a basic ability in the performance area.

ii. The individual is capable of correctly performing the action after some clarification by the examiner.

3. The examiner's evaluation shall be documented.

4. The operational evaluation score for qualification shall be a composite grade of all individual operational evaluations. The composite score for operational evaluations shall be

"satisfactory," with no outstanding "unsatisfactory" items (i.e., 100% of demonstrations must be "satisfactory").

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ENGINEERING STANDARD No. ES-MECH-012 Rev. 2

Chapter 2 Aerial Lifts

MCR-ES-MECH-012,R2-002

2.4 Aerial Lift Personnel Qualification Requirements (Records and

Examinations)

A. Qualification Records

i. Personnel qualifications shall be documented in an easily auditable format and shall include, as a minimum, the following types of information:

a) Records of training completed at PPPL, or elsewhere, such as attendance sheets or computer summaries or certificates.

b) Record of training and performance evaluations.

B. Written Examinations

i. Written examinations with a score of 85% or higher are required to pass any individual examination.

ii. Written examinations are required for initial qualification and every 3 years thereafter.

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ENGINEERING STANDARD No. ES-MECH-012 Rev. 2

Chapter 2 Aerial Lifts

MCR-ES-MECH-012,R2-002

3.0 AERIAL LIFT OPERATOR PERFORMANCE EVALUATION

CHECKLIST

Aerial Lift Operator Performance Evaluation

Operator’s Name Date

(Please Print)

Instructor Supervisor

(Please Print) (Please Print)

For each statement below, check either S (Satisfactory) or U (Unsatisfactory).

For items that do not apply, use NA (Not Applicable).

1. Performed Operator’s Daily Checklist (ODCL) including function test(s).

2. Checked the operational functions of the Aerial Boom from ground control prior to operating from the platform.

3. Mounted the Aerial Boom properly.

4. Observed all danger and warning signs.

5. Did not operate on slope in excess of 5 degrees.

6. Traveled with boom in the stored position.

7. Secured work area(s) prior to operations.

(e.g. roped or coned off area.)

8. Operated equipment only on a stable/firm surface.

9. Cleared obstacles at a safe distance.

10. Demonstrated proper operation of controls.

11. Demonstrated proper maneuvering skills.

12. Used fall protection properly.

13. Performed proper shut down procedure.

14. Raised and operated the Aerial Boom to its highest point.

15. Dismounted the Aerial Boom properly.

16. Refueled/Recharged equipment properly. _______ _______

17. Inspected workplace site for equipment suitability. _______ _______

Restrictions:

Comments:

Approved by:

Instructor’s Signature

TR-Form-28 REV 5 4/2013

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ENGINEERING STANDARD No. ES-MECH-012 Rev. 2

Chapter 2 Aerial Lifts

4.0 MANLIFT OPERATOR’S CHECKLIST OF TRAINING PROVIDED

Operator’s Name_____________________________________________________ Date

Please Print

To be completed after all training is finished Aerial Lift Scissor Lift Truck

Lift

Training Point Covered Not

Covered

1. Operating instructions, warnings, and precautions for the vehicle the operator will be authorized to operate

2. Vehicle controls and instrumentation: where they are located, what they do, and how they work

3. Safety Systems, including interlocks if any, and how they work

4. Engine or motor operation

5. Responsibilities associated with problems or malfunctions affecting the operation of the lift

6. Work place inspection

7. Steering and maneuvering

8. Visibility (including restrictions due to loading)

9. Raising, lowering and positioning of the platform for work

10. Vehicle capacity

11. Vehicle stability

12. Any vehicle inspections and maintenance that the operator will be required to perform

13. Fueling and/or battery recharging

14. Operating limitations

15. Any other operating instructions, warnings, or precautions listed in the operator's manual for the types of vehicle that the employee is being trained to operate

16. Surface conditions where the vehicle will be operated

17. Composition of loads to be raised and load stability

18. Pedestrian traffic in areas where the equipment will be operated

19. Hazardous (classified) locations where the equipment will be operated

20. Ramps and other sloped surfaces that could affect the equipment's stability

21. Closed environments and other areas where insufficient ventilation or poor vehicle maintenance could cause a buildup of carbon monoxide or exhaust

22. Other unique or potentially hazardous environmental conditions in the workplace that could affect safe operation

I confirm that these items were presented in the training

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ENGINEERING STANDARD No. ES-MECH-012 Rev. 2

Chapter 2 Aerial Lifts

MCR-ES-MECH-012,R2-002

Operator’s Signature________________________________________________ TR Form 28/29A 4/2013

5.0 OPERATIONS

Only trained, qualified operators may operate aerial lifts at PPPL. Subcontractors wishing to operate an aerial lift must provide proof of training and certification to the Manlift

Manager to operate the aerial lift they intend to use. All safety requirements must be followed at all times in order to avoid the chance of serious injury or death.

5.1 OPERATIONAL REQUIREMENTS

A. An ODCL inspection shall be performed before every shift, the ODCL form (Section 3.0) shall be kept on the equipment.

B. Only trained and qualified operators carrying a current PPPL Qualification card and driver’s license operate an aerial lift, unless authorized in writing by the Manlift Manager to use training by their employer rather than having a PPPL qualification card.

C. Prior to the operation of any aerial lift, the operator shall have read the operator’s manual for the particular lift being operated.

D. If at any time an aerial lift is found to be in need of repair, defective, or in any way unsafe, the unit shall be tagged out of service until restored to a safe operating condition per PPPL

Procedure ESH-001.

E. Tying off to an adjacent pole, structure, or equipment while working from within an aerial lift is not permitted.

F. Employees shall always stand firmly on the floor of the basket or platform, and shall not sit or climb on the edge of the basket or guardrails. No use of planks, ladders, or other devices is permitted as a work platform from the aerial lift. If exiting the lift at elevation six feet or more above a lower surface, workers must utilize proper fall protection. Workers are permitted to climb the edge of the basket or guardrails only to exit the lift at high elevation, and only when properly protected from falls.

G. All employees using an aerial lift will be equipped with a full body harness and lanyard (fall protection) attached to a designated connection point near the floor of the lift.

H. No operator of an aerial lift may work alone as Fall Protection is a requirement. A minimum of 1 Ground Crew member, who must be a qualified operator for the operation of the ground controls of the aerial lift, must be attendance at all times the lift is in operation.

I. Brakes shall be set and outriggers, when used, shall be positioned on pads or a solid surface.

Wheel chocks shall be installed before using an aerial lift on an incline.

J. Boom and basket load limits shall not be exceeded.

K. No aerial lift truck shall be moved while the boom is in an elevated, working position, with employees in the basket unless the equipment is specifically designed for this type of operation.

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ENGINEERING STANDARD No. ES-MECH-012 Rev. 2

Chapter 2 Aerial Lifts

MCR-ES-MECH-012,R2-002

L. Before moving an aerial lift for travel, the operator shall verify that the boom is properly cradled and the outriggers are stowed.

M. Overhead cranes that can travel through the planned work space that must be locked and tagged out.

N. Fuel tanks shall not be filled with the engine running.

O. Fueling and battery charging shall follow the requirements specified in ES-MECH-014, Refueling and Recharging Vehicles and Equipment.

P. No aerial lift shall be operated with a leak in the fuel system.

Q. Equipment custodians shall keep and maintain a copy of the operating and maintenance manual(s) in the weather resistant storage compartment provided by the manufacturer. The manual(s) is considered an integral part of the aerial lift and is vital to communicate necessary safety information to operators.

R. Before the aerial lift is used and during use, the user shall check the area in which the aerial lift is to be used for possible hazards such as, but not limited to:

i. Drop-offs or holes, including those concealed by water, ice, mud, etc.

ii. Slope(s).

iii. Bumps and floor obstructions.

iv. Debris.

v. Overhead obstructions and high voltage conductors.

vi. Inadequate surface and support to withstand all load forces imposed by the aerial lift in all operating configurations.

vii. Wind and weather conditions.

viii. Presence of unauthorized persons.

ix. Other possibly unsafe conditions.

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ENGINEERING STANDARD No. ES-MECH-012 Rev. 2

Chapter 2 Aerial Lifts

MCR-ES-MECH-012,R2-002

5.2 OPERATING PROCEDURE

Responsibility Action

Aerial Lift

Operator

1. Identifies the aerial lift is the proper equipment for the job.

2. Perform, or verify, a daily inspection of the aerial lift using the proper Operator’s Daily Check List (ODCL) for the aerial lift to be used following the steps in Section 8.0 of this Chapter including verification that the periodic inspection is current.

3. Verify the operator is carrying a current qualification card for operating the aerial lift and any attachments to be used and valid driver’s license.

4. Perform a function test on the aerial lift.

5. Confirm the locations the aerial lift is to be used is suitable for its capabilities.

6. Position the aerial lift in proper location where work is to be performed.

7. Use aerial lift safely to perform work.

8. After completion of job perform the Shut Down Procedure per the

Operator’s Manual.

9. Submit the full Signature Sheet to the Equipment Contact.

Equipment

Contact

10. Check aerial lift periodically to assure that completed sign off sheets are turned in. Submits all completed sign off sheets to their supervisor.

Supervisor 11. Signs and send the Signature Sheet to the Operations Center for filing.

12. Periodically check that the ODCL has been performed on the aerial lift, initial and date the ODCL.

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ENGINEERING STANDARD No. ES-MECH-012 Rev. 2

Chapter 2 Aerial Lifts

6.0 ODCL SIGN OFF SHEET

Contact’s Supervisor Signature_____________________________________________ Date _____________________

Send to Operations Center for filing

Revised 2/14/13

7.0 TRAVELLING

A. The operator shall limit travel speed according to conditions such as:

i. Condition of surface support

ii. Visibility

iii. Slope

iv. Location of personnel

v. Any other factors leading to hazards

B. Stunt driving is prohibited

C. Area personnel must be aware of the unit’s travel

D. A safe distance shall be maintained from all hazards while traveling

8.0 INSPECTION

8.1 DAILY INSPECTIONS

A complete listing of Operator’s Daily Check Lists for all equipment may be found at the follow site:

https://sites.google.com/a/pppl.gov/equipment-safety-inspection-list/

ODCL INSPECTION SIGN OFF

Equipment Conact ______________________________

Equipment: __________________________

Prop. #: _____________________________

DATE TIME CHK BY (print name)

PASS

(X)

FAIL

(X) COMMENTS

Note: if the machine does not pass ODCL inspection, tag the machine out of service, do not use the machine and notify supervisor immediately explaining the cause of the failure.

Contact

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ENGINEERING STANDARD No. ES-MECH-012 Rev. 2

Chapter 2 Aerial Lifts

MCR-ES-MECH-012,R2-002

ODCL’s shall be maintained by Material Services, changes may be authorized by the Subject

Matter Expert (see Attachment 1, Page 1). Before use each day or at the beginning of each shift, the aerial lift shall be given an Operator’s Daily Check List inspection consisting of visual inspection and functional tests including but not limited to the following:

A. Platform assembly for loose or missing parts.

B. Slave cylinder for damage or leaks.

C. Boom sections, hoses and cylinders for damage or leaks.

D. Drive motor and brakes.

E. Operating and emergency controls for proper functioning.

F. Safety devices.

G. Air, hydraulic and fuel system levels and leaks.

H. Cables and wiring harness.

I. Loose or missing parts.

J. Tires and wheels.

K. Placards, warnings, control markings, and operating manual(s).

L. Outriggers, stabilizers, and other structures.

M. Guardrail system.

N. Items specified by the manufacturer.

O. The daily ODCL shall be maintained in holders installed on each aerial lift. The ODCL inspector will sign the Signature Sheet at the completion of the inspection if there are no concerns. The Signature Sheet will be given to the aerial lift’s Contact’s Supervisor when full. The Supervisor will send the Signature Sheet to the Operations Center for record keeping once the sheet has been signed and completed.

P. If during the inspection of the aerial lift it is found to be in need of repair or becomes unsafe in any way, it shall be reported to the operator’s supervisor immediately and the aerial lift shall be tagged out, with a Caution Tag, and not be operated until repaired and restored to a safe operating condition. The Operator’s Supervisor will contact the Manlift Manager for service.

8.2 FREQUENT INSPECTIONS

NOTE: Due to the low operational hours for some aerial lifts, sections of the frequent inspection criteria may be moved to less often inspections if warranted and documented using the ODCL change form found in Attachment 1, Page 1. In no case shall any inspection time frame be greater than 1 year.

The Manlift Manager shall ensure that frequent inspections are performed in accordance with the manufacturer’s instructions, for the aerial lift. Any malfunctions and problems identified in the inspection shall be corrected before the aerial lift is returned to service.

Inspections are typically required for:

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ENGINEERING STANDARD No. ES-MECH-012 Rev. 2

Chapter 2 Aerial Lifts

MCR-ES-MECH-012,R2-002

A. Equipment that has been in service for three (3) months or 150 hours, whichever comes first;

B. Equipment that has been out of service for a period longer than three months;

C. Equipment that was purchased used;

The inspection shall be made by a person qualified as a mechanic on the specific type of aerial lift or one having similar design characteristics. The inspection shall be in accordance with items specified by the manufacturer for a frequent inspection and shall include, but not be limited to the following:

A. All functions and their controls for speed(s) smoothness, and limits of motion;

B. Lower controls including the provisions for overriding of upper controls

C. All chain and cable mechanisms for adjustment and worn or damaged parts;

D. All emergency and safety devices;

E. Lubrication of all moving parts, inspection of filter element(s), hydraulic oil, engine oil, and coolant as specified by the manufacturer;

F. Visual inspection of structural components and other critical components such as fasteners, pins, shafts and locking devices as specified by the manufacturer;

G. Placard, warnings and control markings;

H. Emergency lowering means;

I. Additional items specified by the manufacturer.

8.3 ANNUAL INSPECTIONS

The Fleet Coordinator shall ensure that an annual inspection is performed on the aerial lifts no later than thirteen (13) months from the date of the prior annual inspection. The inspection shall be performed by a person(s) qualified as a mechanic on the specific make and model of the aerial lift or one having similar design characteristics. The inspection shall be in accordance with items specified by the manufacturer for an annual inspection. The equipment custodian shall not place the aerial lift into service until all malfunctions and problems have been corrected.

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ENGINEERING STANDARD No. ES-MECH-012 Rev. 2

Chapter 2 Aerial Lifts

MCR-ES-MECH-012,R2-002

9.0 MAINTENANCE AND REPAIR

A. PROCEDURE FOR OBTAINING MAINTENANCE AND REPAIR FOR AERIAL LIFTS

Responsibility Action

Fleet Coordinator 1. Maintain the inspection records for periodic inspection/maintenance.

Monitors due dates for periodic inspections/maintenance and notifies the equipment owners and Manlift Manager of actions required to maintain compliance.

Manlift Manager 2. When the aerial lift is approaching the expiration date for maintenance or inspection, initiates the procurement paperwork to have a qualified inspector or outside vendor perform the work. If the maintenance or inspection is not completed the aerial lift shall be CAUTION tagged

OUT OF SERVICE until such time as the required actions are completed per PPPL Procedure ESH-001.

3. Determine if each aerial lift is to be kept in service.

a. If aerial lift is not to be kept in service, request the equipment owner to CAUTION tag item OUT OF SERVICE per PPPL Procedure

ESH-001.

4. Determine when, during the calendar year, each aerial lift annual inspection/maintenance is due.

Qualified Inspector or

Qualified

Subcontractor

5. Perform required aerial lift maintenance per the manufacturer’s recommendations and periodic inspection as per the aerial lift Inspection

Criteria under observation of Manlift Manager or a technically qualified designee.

Note: Prior to the commencement of any service or repair, the aerial lift shall be turned off with the key removed and in the possession of the repairman. Any potential energy (such as a raised platform) shall be blocked or restrained. (Per OSHA response regarding 1910.147 -

9/27/95) Any sources of hydraulic pressure shall be removed or released. If the service or repair requires work in the engine compartment, then the aerial lift battery cable shall be disconnected as well (Cable shall be tagged with a Danger Tag if service person must be away from unit).

6. Record the inspection/maintenance on a Service Report (Attachment 2) while on site and sign report(s) and give them to the Manlift Manager or a technically qualified designee.

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ENGINEERING STANDARD No. ES-MECH-012 Rev. 2

Chapter 2 Aerial Lifts

MCR-ES-MECH-012,R2-002

A. PROCEDURE FOR OBTAINING MAINTENANCE AND REPAIR FOR AERIAL

LIFTS

(continued)

Manlift Manager 7. Determine if deficiencies are found.

a. If no, sign and submit service report to the Fleet Coordinator, copy to

Manlift Manager, and affix inspection sticker, showing expiration date to the aerial lift, and to the attachment if so equipped.

b. If yes, sign and submit service report to Fleet Coordinator, copy to

Manlift Manager, and apply CAUTION tag OUT OF SERVICE

PPPL Procedure ESH-001.

Fleet Coordinator 8. Review and file all service reports and update inspection status list.

B. REQUIREMENTS FOR MAINTENANCE AND REPAIR FOR AERIAL LIFTS

i. When parts or components are replaced, they shall be OEM aerial lift parts or components equivalent as to the safety of those used in the original design.

ii. Prior to the commencement of any service or repair, the aerial lift shall be turned off with the key removed and in the possession of the repairman. Any potential energy

(such as a raised platform) shall be blocked or restrained. (Per OSHA response regarding 1910.147 - 9/27/95) Any sources of hydraulic pressure shall be removed or released. If the service or repair requires work in the engine compartment, then the aerial lift battery cable shall be disconnected as well (Cable shall be tagged with a

Danger Tag if service person must be away from unit).

iii. The Manlift Manager shall ensure only qualified personnel inspect and maintain the aerial lift in accordance with the manufacturer’s recommendations.

iv. Maintenance shall be performed according to the manufacturer's recommendations and as a minimum shall meet the requirements of OSHA 29 CFR 1910, OSHA 29 CFR

1926, ESH-001 (Tagout).

a. Power plant shall be stopped and starting means rendered inoperative.

b. All controls in the off position and all operating systems secured from inadvertent motion by brakes, blocks or other means.

c. Elevating assembly and platform lowered to the full down position or otherwise secured by blocking or cribbing to prevent dropping.

d. Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components.

e. Other manufacturer specified precautions.

v. Scheduled maintenance, lubrication and inspection shall be based on the manufacturer’s recommendations.

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ENGINEERING STANDARD No. ES-MECH-012 Rev. 2

Chapter 2 Aerial Lifts

MCR-ES-MECH-012,R2-002

vi. Only trained and authorized personnel shall be permitted to maintain, repair, adjust and inspect aerial lifts.

vii. Unusual maintenance or repairs require consultation with the manufacturer and approval of the Manlift Manager.

B. REQUIREMENTS FOR MAINTENANCE AND REPAIR FOR AERIAL

LIFTS (continued)

viii. Aerial lifts shall not be altered so that the relative positions of the various parts are different from what they were when originally received from the manufacturer, nor shall they be altered either by the addition of extra parts not provided by the manufacturer or by the elimination of any parts. Any manufacturer approved changes must also be approved by the Manlift Manager.

ix. Repaired Aerial lifts shall be inspected prior to be returned to service by qualified inspectors or sub contractors. The service report will be signed by the service person and the Manlift Manager, or the Designee, and be given to the Fleet Coordinator to be filed in the equipment’s file.

x. Safety switches and functionality shall not be impaired by service technicians.

10.0 IDENTIFICATION

Every aerial lift shall have attached to it a legibly inscribed, corrosion-resistant nameplate with the model and/or serial number, weight of the lift, and the capacity of the lift at maximum elevation with load laterally centered.

11.0 TRANSPORTING/TOWING

If an aerial lift is to be transported or towed, the operator’s shall follow all of the manufacturer’s requirements found in the manuals for the unit.

12.0 MODIFICATIONS

A. Modifications to equipment are a rare requirement. (Modifications should not be confused with the use of manufacturer approved and supplied attachments designed to be used with the equipment.)

B. Equipment shall not be altered so that the relative positions of the various parts are different from what they were when originally received from the manufacturer, nor shall they be altered either by the addition of extra parts not provided by the manufacturer or by the elimination of any parts without manufacturer’s written approval.

C. All requests for modifications should be documented on the form in Attachment 1, Page 2, Request to Alter Equipment. No changes can be made until the manufacturer provides written approval for the modification. A copy of E-mail correspondence documenting requests and manufacturer’s approvals may be used as written approval. All requests and manufacturer’s approvals must be kept in the equipment’s file.

Printed copies of this document are considered UNCONTROLLED / Information Only copies. The official document is at

ENGINEERING STANDARD No. ES-MECH-012 Rev. 2

Chapter 2 Aerial Lifts

MCR-ES-MECH-012,R2-002

D. If the manufacturer is unresponsive for more than a year or if the manufacturer no longer exists, alterations to equipment may only be made using the Request to Alter Equipment

Form, Attachment 1, Page 2, with the PPPL Subject Matter Expert’s approval of the modification and the concurrence of a Professional Engineer (OSHA response 4/11/97, Question 1). All requests and SME/PE approvals must be kept in the equipment’s file.

E. When approved modifications are made, appropriate changes to capacity plates, operation and maintenance manuals, any affected decals and/or tags must reflect any modifications.

F. After any modifications, the equipment must be inspected by a qualified inspector.

13.0 RECORDS

A. Inspection reports shall be maintained by Material Services.

B. Records shall be retained in the Material Services Transportation Services master files for the life of the equipment while at PPPL.

C. The equipment file for each unit shall include:

i. Serial number and date of delivery.

ii. Written records of the frequent and annual inspections and repairs performed. The record shall include deficiencies found, corrective action accomplished and identification of the person(s) performing the inspection and repairs.

iii. Written records of repairs accomplished on the aerial lift. The records shall include corrective action accomplished and identification of the person(s) performing the repairs.

iv. Pre-delivery preparation performed prior to each delivery.

a. Name of the person(s) trained.

b. Name of person(s) providing training.

c. Name of person(s) receiving familiarization upon delivery, unless the individual has been provided with familiarization on the same model, or one having characteristics consistent with the one being delivered, within the prior 90 days

d. Name of person(s) providing familiarization upon delivery.

14.0 INITIAL INSPECTIONS

A. Prior to initial use, all new, rented, or extensively repaired or altered aerial lifts shall be tested and inspected by a qualified person or inspector.

ATTACHMENTS:

1. ODCL Change Request Form and Equipment Alteration Request Form

2. Service Report

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PPPL

PHYSICS LABORATORY PROCEDURE ES-MECH-012 Rev 2

Attachment 1

Chapter 2 Aerial Lifts - ODCL Change Request Form Page 1 of 2

Request to move inspection item from Daily to Monthly

Equipment Type _______________________________________________________

Manufacturer _____________________________ Model_________________________________

Serial Number(s)______________________________________________________________________

Property Number(s)___________________________________________________________________

Equipment Contact(s) _________________________________________________________________

Equipment Custodian(s) ________________________________________________________________

Subject Matter Expert __________________________________________________

Item to be moved Reason for move Frequency of Inspection item is moved to

Requested by: ______________________________________________________ Date ____________

Approved by: _______________________________________________________ Date ____________ Subject Matter Expert

Comments___________________________________________________________________________

Distribution: __________________________, _______________________, _____________________, Approved form to be filed by Material Services with the ODCL Masters Revised 10/21/13

Printed copies of this document are considered UNCONTROLLED / Information Only copies. The official document is at

PPPL

PHYSICS LABORATORY PROCEDURE ES-MECH-012 Rev 2

Attachment 1

Chapter 2 Aerial Lifts - Request to Alter Equipment Page 2 of 2

MCR-ES-MECH-012,R2-002

Request to Alter Equipment

Manufacturer ___________________________ Model_________________________________

Serial Number(s)___________________________________________________________________

Property Number(s) ________________________________________________________________

Equipment Contact(s) ______________________________________________________________

Equipment Custodian(s) _____________________________________________________________

Subject Matter Expert ______________________________________________________________

Manufacturer’s Approval Letter ID ____________________________________________________

Provide detail of changes/modifications requested and reasons:

Requested by: ____________________________________________________ Date ______________

Approved by: _____________________________________________________ Date ______________ Subject Matter Expert

Approved by: _____________________________________________________ Date ______________ Professional Engineer

Comments___________________________________________________________________________

Distribution: _________________________, _______________________, _______________________

Approved form to be filed by Material Services in equipment file Revised 10/21/13

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ENGINEERING STANDARD No. ES-MECH-012 Rev. 2

Attachment 2

Chapter 2 Aerial Lifts - Service Report Page 1 of 2

PPPL Equipment Service Report

When service work has been completed: Sat Unsat

1. Perform Operator’s Daily Checklist Inspection

2. Every Inspection – Check that all safety devices, interlocks, lights and alarms are functioning properly

3. All product recalls and safety improvements have been installed.

NOTE: Any and all malfunctioning safety devices, interlocks, lights and alarms must be brought to the immediate attention of the PPPL escort regardless of the nature of the service call.

Additional writing space on reverse

Equipment Type _____________________________________________ Date __________________

Serial Number_______________________________________________________________________

Property Number_____________________________________________________________________

Equipment Problem/Service Requested: Requestor:_____________________________-

Work/Service Performed and comments:

When service work has been completed: Sat Unsat

1. Perform Operator’s Daily Checklist Inspection

2. Every Inspection - Check that all safety devices, interlocks, NOTE: Any and all malfunctioning safety devices, interlocks, lights and alarms must be brought to the

Check One: (PASS – SATISFACTORY TO USE) (FAIL)

INSPECTOR (PRINT): SIGNATURE: DATE:

Check One: (PASS – SATISFACTORY TO USE) (FAIL – TAGGED OUT, PTR NOTIFIED)

Escort (PRINT): SIGNATURE: DATE:

This form must be completed at end of service call, give to Fleet Coordinator, copy to PTR

T o b e co m p le te d b y S er v ic e T ec h n ic ia n o b e co m p le te d b y P

P P

L

Equipment Type _____________________________________________ Date __________________

Serial Number_______________________________________________________________________

Property Number_____________________________________________________________________

Equipment Problem/Service Requested: Requestor:_____________________________-

Work/Service Performed and comments:

When service work has been completed: Sat Unsat

1. Perform Operator’s Daily Checklist Inspection

2. Every Inspection - Check that all safety devices, interlocks, NOTE: Any and all malfunctioning safety devices, interlocks, lights and alarms must be brought to the

Check One: (PASS – SATISFACTORY TO USE) (FAIL)

INSPECTOR (PRINT): SIGNATURE: DATE:

Check One: (PASS – SATISFACTORY TO USE) (FAIL – TAGGED OUT, PTR NOTIFIED)

Escort (PRINT): SIGNATURE: DATE:

This form must be completed at end of service call, give to Fleet Coordinator, copy to PTR o b e co m p le te d b y S er v ic e T ec h n ic ia n o b e co m p le te d b y P

P P

L

Printed copies of this document are considered UNCONTROLLED / Information Only copies. The official document is at

ENGINEERING STANDARD No. ES-MECH-012 Rev. 2

Attachment 2

Chapter 2 Aerial Lifts - Service Report Page 2 of 2

MCR-ES-MECH-012,R2-002

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ENGINEERING STANDARD No. ES-MECH-012 Rev. 2

Chapter 3 Scissor Lifts

1.0 INTRODUCTION

This chapter covers both self propelled and manually propelled elevating work platforms. These types of work platforms will be referred to as scissor lifts. Please note that as of this writing, OSHA classifies scissor lifts under the scaffolds regulations.

For all electrical work requiring the use of scissor lifts, the requirements for aerial lifts and aerial work found in OSHA 1910.269 shall apply.

2.0 TRAINING

2.1 TRAINING REQUIREMENTS

Training shall consist of a combination of documented instruction (e.g., lecture, discussion, interactive computer learning, video, and/or written material), practical training (demonstrations performed by the Instructor and practical exercises performed by the trainee), and evaluation of the operator's performance in the workplace.

A. Personnel who have not been trained to operate scissor lifts may operate a scissor lift for the purposes of training only, and only under the direct supervision of the Instructor. This training should be conducted in an area away from other vehicles, obstacles, and pedestrians.

B. All operator training and evaluation shall be conducted by persons who have the knowledge, training, and experience to train operators and evaluate their competence. Instructor qualifications will be evaluated and documented by Human Resources per TR-005

C. The following topics will be covered in the training program of scissor lifts.

i. Operating instructions, warnings, and precautions;

ii. Vehicle controls and instrumentation: where they are located, what they do, and how they work;

iii. Safety Systems, including interlocks if any, and how they work;

iv. Engine or motor operation;

v. Responsibilities associated with problems or malfunctions affecting the operation of the lift;

vi. Work place inspection;

vii. Steering and maneuvering;

viii. Visibility (including restrictions due to loading);

ix. Raising, lowering and positioning of the platform for work;

x. Vehicle capacity;

xi. Vehicle stability;

xii. Any vehicle inspections and maintenance that the operator will be required to perform;

xiii. Fueling and/or battery recharging;

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ENGINEERING STANDARD No. ES-MECH-012 Rev. 2

Chapter 3 Scissor Lifts

MCR-ES-MECH-012,R2-002

2.1 TRAINING REQUIREMENTS (continued)

xiv. Operating limitations;

xv. Any other operating instructions, warnings,…