TITLE:

ES&H Manual

 

DOCUMENT ID:

6146 Tunnel Vehicles

 

 

1.0            Purpose

 

Due to the limited space and air quality requirements, the only type of vehicles permitted in the tunnel are those which do not produce any emissions.

 

This chapter covers the use of powered industrial vehicles both Electrical & Self Propelled in the Accelerator Tunnel, i.e., Wheeled Tow Carts, Electric Forklifts, and Powered Low Lift Pallet Jacks.  This chapter however, does not cover any aspect of Powered Industrial Vehicles being used in the Experimental Halls, FEL Vault, or around Jefferson Lab site outside of the Accelerator Tunnel.

 

Jefferson Lab has a diverse inventory of Industrial Powered Vehicles as referred to by OSHA in 29 CFR Part 1910.178 and its Appendix A for material handling and transportation.  They range from bicycles to mobile cranes.  Several of the ES&H Manual chapters focus on these particular types of vehicles, refer to:

 

·         ES&H Manual Chapter 6140 Cranes and Hoists

·         ES&H Manual Chapter 6145 Forklift Safety

·         ES&H Manual Chapter 6147 Aerial Work Platforms

·         ES&H Manual Chapter 6170 Motor and On-Site Transportation  (Including personal automobiles, GSA Vehicles, State Owned cars, golf carts, and any other powered vehicle used at Jefferson Lab.)

 

There are four 3-wheeled tow carts normally kept in the tunnel, these pieces of equipment are used by authorized personnel for transporting themselves and equipment around the tunnel.  They normally reside in the tunnel and are parked in the tunnel crane access pit areas during beam operations.

 

Forklifts are only in the tunnel for specific periods (i.e., Scheduled Accelerator Downs) when the beam is not in operation and a forklift is required for a specific task (i.e., installing a magnet).

 

Powered Low Lift Pallet Jacks are also only brought into the tunnel for specific tasks and periods.  They are used to move heavy objects such as pallets of concrete shielding blocks around the tunnel and are only operated by authorized and trained individuals.

 

2.0            Types of Vehicles and Their Uses

 

The only types of vehicles are:

 

·         3-Wheel Tow Carts

·         Forklifts - Electric Only

·         Powered Low Lift Pallet Jacks

·         Aerial Platforms/Manlifts-Electric Only

 

3-Wheel Tow Carts Usage:

·         Towing large and/or heavy pieces of equipment on trailers or special transportation devices, i.e., Cryomodules, dipole transport carts.

·         Transporting tools, equipment or materials around the tunnel.

 

Forklifts - Electric Only Usage:

·         Installing or removing heavy pieces of equipment, i.e., dipoles, large vacuum chambers, girders, etc.

 

Powered Low Lift Pallet Jack Usage

·         Moving pallets of equipment or material around the tunnel.

 

Aerial Platforms/Manlifts - Electric Only Usage

·         Provide an elevated stable work platform.

 

3.0            Hazard Avoidance

 

Due to the very limited space within the Accelerator tunnel, additional care must be taken when operating equipment in the tunnel.  There are also additional responsibilities for the operators and their supervisors due to this space limitation.  These are documented in the appropriate sections of this chapter.

 

Additional planning and advance notification of intended work to affected areas are also required due to the size of the equipment, the routes they can travel and the proximity to other people working around the tunnel.  It is strongly advised that when preparing to use a powered industrial vehicle in the tunnel, the route first be walked by the operator or their supervisor to check for obstacles, i.e., vacuum carts or pumps, installation equipment, or personnel involved in ongoing work.  One day or more in advance, supervisors should attend the morning scheduling meeting held every morning in the MCC Conference Room and notify all parties of their intentions and resolve conflicts.

 

An approved written Lift Plan shall be used for the “lowering into and lifting out of” the Access Building crane pits of the Powered Industrial Vehicles.  The positions for the straps to lift the equipment safely shall be marked on the equipment with RED paint.

 

4.0            Responsibilities

 

Vehicle Operators

·         Shall perform normal equipment inspections prior to using the equipment.

·         Shall report any collision with any piece of the Accelerator to their supervisor and/or the owner of the equipment which was struck even if there is no outward sign of damage.

·         Shall operate the equipment in accordance with Jefferson Lab’s ES&H Manual Chapter 6145 Forklift Safety, ES&H Manual 6147 Aerial Work Platforms, and ES&H Manual 6170 Vehicles and On-Site Transportation as appropriate.

·         Shall operate the equipment with extra care and vigilance due to the space limitations.

·         If during the operation of equipment a pedestrian needs to pass, allow them to do so as soon as it is safe and convenient to do so.  Again common sense and courtesy are the preferred rule.

·         Do not permit any riders on equipment unless the equipment is specifically designed for that purpose.

·         Shall not modify equipment without manufacturer’s prior written approval.

·         Shall not tow equipment without a proper hitch or linkage method.

 

Supervisors

·         Shall ensure that the personnel assigned to or under their purview that operates equipment in the tunnel are qualified and are confident they can perform their assigned tasks safely.

·         Shall report any collisions to the Operability Manager.

·         Shall provide additional supervision when training new operators in the tunnel.

·         Coordinate tasks requiring forklift operation in the tunnel with the Operability Manager or their designee.  Also notify the Operability Manager whenever a forklift is placed into or removed from the tunnel.

 

Operability Manager

·         Approve tunnel forklift operators.

·         Manage material movement priorities.

·         Coordinate investigation of any collision damage and repair of equipment if required.

 

Facilities Management

·         Provide maintenance and repair support for the tunnel vehicles (3 wheeled tow carts).

·         Maintain all documentation of maintenance performed on the 3 wheeled tow carts.

·         Coordinate for the removal of equipment, to be repaired or serviced, from the tunnel.

 

5.0            Qualifications

 

Operators

Due to the limited space in the tunnel, only experienced operators who have demonstrated above normal proficiency in the operation of forklifts shall be permitted to operate them in the tunnel.

 

6.0            Procedure

 

Individual

·         Pedestrians have right of way, however, common sense and courtesy are the preferred rule.

·         If an individual is working on a ladder, he or she shall dismount while a vehicle passes.

·         When a pedestrian is passing powered equipment in operation, they shall ensure that the operator is aware of their intentions prior to passing the equipment and that the operator gives their permission.  This is especially important during magnet installation when a forklift is being operated and the operator’s attention is focused solely on the job at hand.

 

Operators

·         During inspection or operations, if a piece of equipment is found to be defective, the operator shall tag out the equipment and notify Facilities Management at ext. 7400.

·         Pedestrians have right of way, however, common sense and courtesy are the preferred rule.

·         When passing an individual, ensure they are aware of your presence.  Electric tow carts and forklifts move quietly and the sudden realization of the equipment’s presence may cause alarm and an accident.

·         Should check the transit route before starting out, especially when going long distances around the tunnel.  This is to ensure there are no obstacles to passage or equipment that should be moved.  If vacuum pumps need to be moved to permit transit, additional care should be taken not to trip the pumps off.  If necessary, contact the Vacuum Group and have one of their technicians move the equipment.  Any questions should be directed to the operator’s supervisor.

 

Supervisors

·         When long duration tasks (i.e., magnet installation or removal) are being performed, cordon off the section of the tunnel to prevent pedestrian traffic for the duration of the work.

 

7.0            Battery Charging

 

Tunnel Equipment Battery Charging

There are basically two types of battery charging systems employed by this equipment in the tunnel:

 

1.      Self contained or built in type:

This is actually built into the equipment as with the 3 wheeled tow carts and cannot be removed from the equipment without disassembly of it.

2.      Free Standing Charging Stations Type:

This is independent of the equipment as with the forklifts and powered low lift jacks. It can be located at a convenient area which is set up with the required additional safety supplies.

 

Battery Charging of Equipment with Built In Charging Systems

This refers to the 3-Wheeled Tow Carts however it also covers any other piece of equipment with a built in battery charging system.  There are no special precautions to be taken.

 

There is a power cord permanently attached to the equipment that is simply plugged into a convenient wall receptacle in either the North or South Access Building crane pits.  The equipment will then automatically start charging its batteries.

 

Note: As with any other piece of equipment, the power cord shall be inspected as per Jefferson Lab Environmental, Safety, Health, and Quality (ESH&Q) established policies and practices.  If there are any questions about the condition of the power cord, they should be directed to your supervisor or a qualified electrical worker.

 

Extension cords shall not be used in this operation unless specifically approved in ES&H Manual Chapter 6210 Appendix T2 Extension Cord Safety for such purpose.

 

Battery Charging of Equipment with Free Standing Charging Stations, (i.e., Forklifts & Powered Low Lift Pallet Jacks)

 

All tunnel forklifts shall be charged only at the battery charging stations (with portable eye wash station) under the hatch in either the North or South Access Building.  These areas have adequate volumes to prevent build-up of the gases generated during battery charging.

 

·         Eye protection must be worn when charging the equipment and adding water to the batteries.

·         Charger must be in the “off” position when being connected or disconnected.

·         Precautions shall be taken to prevent open flames, sparks, or electric arcs in battery charging areas.

 

Note: Disposal of all used, defective or unwanted batteries shall be through the Jefferson Lab ESH&Q Industrial Hygiene Group.

 

 

 

ISSUING AUTHORITY

CHAPTER AUTHOR

APPROVAL DATE

EFFECTIVE DATE

EXPIRATION DATE

REV.

 

 

 

ESH&Q Division

Jennifer Williams

03/31/06

03/31/06

03/31/09

0

 

This document is controlled as an on line file.  It may be printed but the print copy is not a controlled document.  It is the user’s responsibility to ensure that the document is the same revision as the current on line file.  This copy was printed on 8/14/2009.