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<td><a href="https://misportal.jlab.org/ll/index.jsf?function=view&lessonId=868">Industrial Equipment Impacts to Facility’s Infrastructure – Various Locations</a></td>
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<h2 style="white-space:nowrap">Statement of Lessons Learned</h2>
<pre>For a copy of the original report, see “Attachments” on Lessons Learned page.
This Lesson Learned provides a summary of a variety of incidents where heavy industrial equipment damaged structures and electrical, gas, and water lines. Although these incidents did not cause injuries, the events did impact work schedules, diverted resources, and changed task momentum. Work planning and control processes were initiated, however, for one reason or another, they did not address all possibilities.
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<h2 style="white-space:nowrap">Discussion of Activities</h2>
<pre>From January 1, 2011, to June 30, 2014, more than two dozen Department of Energy (DOE) noninjury events were reported regarding equipment striking something for reasons ranging from lack of communication between or within departments before work started, unmarked utilities, as-builts not matching drawings, unsuccessful locate efforts, or inadequate ground-penetrating radar. A variety of equipment was involved, including backhoes, forklifts, and excavators. Although no injuries resulted from the events reported to the Occurrence Reporting and Processing System (ORPS), the potential for harm existed. The events resulted in property damage, stopped work, and increased time and resources to complete the interrupted tasks.</pre>
<h2 style="white-space:nowrap">Analysis</h2>
<pre>On March 24, 2014, at the Pittsburgh National Energy Technology Laboratory, an equipment operator using a backhoe to excavate for a water line installation hit a 2-inch natural gas line, resulting 'in a low audible hissing sound and the smell of natural gas (mercaptan). Work was stopped, while the gas line was repaired and tested.
On February 18, 2013, during exploratory excavations at the Portsmouth Gaseous Diffusion Plant, a backhoe bucket hit two underground power cables, slightly damaging the outer insulation and exposing bare wire.
In October 2012, Y-12 filed a report describing 21 incidents involving powered industrial truck (forklift) operations over a 2-year period. Although only two events were ORPS-reportable, management concluded that there was a potential for personnel injury during forklift operations and the negative trend constituted a management concern. Events included a forklift striking two pillars; forklift tines contacting loading dock flashing and pulling it loose; and a forklift boom contacting and breaking an abandoned communication line.
On June 25, 2012, at Idaho National Laboratory, as a heavy equipment operator pulled up asphalt with a back hoe, making contact with an electrical conduit.
On April 25, 2012, at Oak Ridge National Laboratory, an excavator contacted and damaged a Polyvinyl Chloride conduit containing a 120-volt electrical cable while digging a trench for electrical lines.
On April 12, 2012, an electrical subcontractor using a trencher, hit and punctured a marked natural gas line.
On February 3, 2012, at Los Alamos National Laboratory, a front end loader clearing an area covered in 1 to 3 feet of snow severed a 480-volt power cord buried 2 inches below the surface. The rough terrain caused the bucket to dip below grade, where it contacted the buried cord.
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<h2 style="white-space:nowrap">Recommended Actions</h2>
<pre>Below are the consequences of the above event. They are provided for information and discussion purposes only.
The following recommendations for the safe operation of industrial equipment are provided as examples only. They are based on the corrective actions performed as a result of the previous events.
• Require the use of spotters.
• Modify construction subcontracts to indicate a zero tolerance policy for violations of safety or work rules. Deviations in scope to result in immediate suspension of work until hazards associated with the change(s) have been identified and controls put into place.
• Modify construction subcontracts to require safety training; develop training to cover construction safety, work control, job hazard analysis, and performance.
• Verify employee training /certification. Perform evaluations of heavy equipment operators to assess ability and competency.
• Include "situational awareness" in training.
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<h2 style="white-space:nowrap">JLab Preventive Measures</h2>
<pre>Jefferson Lab requires additional training for workers who operate material handling equipment. This training includes the recommended corrective actions.</pre>
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<h2>Comments</h2>
<h5 style="white-space:nowrap">1/7/2015 2:38:08 PM by Bailey, Mary Jo</h5>
<pre>Submitted to those who have been trained to operate material handling equipment.</pre>
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<legend>Summary</legend>
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<td class="label" nowrap>Lesson ID:</td>
<td class="dataval">868</td>
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<td class="label" nowrap>Status:</td>
<td class="dataval">OK</td>
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<td class="label" nowrap>Doc ID:</td>
<td class="dataval">2015-JLAB-868</td>
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<td class="label" nowrap>Priority:</td>
<td class="dataval">Info</td>
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<td class="label" nowrap>Safety Related:</td>
<td class="dataval">YES</td>
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<td class="label" nowrap>Originator:</td>
<td class="dataval">Bailey, Mary Jo</td>
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<td class="label" nowrap>Issued:</td>
<td class="dataval">1/7/2015 2:37:15 PM</td>
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<td class="label" nowrap>Approved By:</td>
<td class="dataval">Bailey, Mary Jo</td>
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<td class="label" nowrap>Approved On:</td>
<td class="dataval">1/7/2015 2:38:08 PM</td>
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<td class="label">Source:</td>
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DOECRD
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<td class="label" nowrap>Location:</td>
<td class="dataval">OTHER</td>
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<td class="label" nowrap>Cost Savings:</td>
<td class="dataval"></td>
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<td class="label" nowrap>Contact:</td>
<td class="dataval">Direct Questions to Ashley Ruocco at 301-903-7010 or ashley.ruocco@hg.doe.gov.</td>
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<td class="label" nowrap>Queued Emails:</td>
<td class="dataval">0</td>
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<td class="label" nowrap>Sent Emails:</td>
<td class="dataval">0</td>
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<td class="label" nowrap>Viewings:</td>
<td class="dataval">2 times</td>
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<legend>Attachments</legend>
<a name="attachments"></a>
<ul class="lesson_attribute_listing">
<li><a target="_blank" href="https://misportal.jlab.org/ll/downloadAttachment?attachmentId=3620">OE-3_2014-06.pdf</a></li>
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<legend>Hazard Issues</legend>
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<li>Material Handling Equipment</li>
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<legend>Skills</legend>
<ul class="lesson_attribute_listing">
<li>SAF300: AERIAL WORK PLATFORM</li>
<li>SAF402: CRANE OPERATION AND RIGGING</li>
<li>SAF502: FORKLIFT OPERATOR</li>
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<legend>Distribution/Notification</legend>
<ul class="lesson_attribute_listing">
<li>*Division Safety Officers (DSOs)</li>
<li>*Safety Wardens</li>
<li>*DOE Notification</li>
<li>*ESH&Q Liaisons</li>
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Do you have a lesson learned you would like to contribute? Contact the <a href="mailto:cjohnson@jlab.org,sjsmith@jlab.org,mbailey@jlab.org">Lesson Learned Coordinator</a>.