STANDARD WORK PROCEDURE...202 STANDARD WORK PROCEDURE No: SURDIA5.01 Prepared By: Vaughan Cullen Title: Running/Pulling and Seating Approved By: Vaughan Cullen Casing and the Start

201

STANDARD WORK PROCEDURE

No: SURDIA5.01 Prepared By: Vaughan Cullen

Title: Running/Pulling and Seating Approved By: Vaughan Cullen

Casing and the Start of the hole-Haul Plug Revision Date: 11th Oct 2010 Reviewed By: Lawrie Lorrigan

STEP SPECIFIC JOB STEPS HAZARDS WITHIN THIS STEP

(Safety and Environmental) RISK LEVEL

SCORE HAZARD CONTROL ACTIVITY REQUIRED

RESIDUAL RISK

SCORE

18 Offsider directs rod onto sloop/truck Personal injury – hands 16

Moderate

Never place fingers inside rods or position your hand lower then 300mm from the top of the pin.

Gloves must be worn Follow correct manual handling procedures Maintain good communication Ensure good balance Follow good housekeeping policies

4 Low

19 Lower rod Personal injury – rod falls Equipment damage

16 Moderate

Never stand under suspended load. Lower at controlled speed. Once the rod in on the rack/sloop ensure all crew are in a safe position. Watch the haul plug/winch as the rod comes down the mast to ensure correct positioning and lifting gear is tight/in place.

4 Low

20 Unscrew pulling plug end screw into next red Personal injury – hands 16

Moderate

Insure all pressure in rod string is released before attempting to remove pulling plug. Monitor condition of the subs and lifting gear

4 Low

21 Repeat steps 14 to 21 until all rods are removed

WARNING

202



Title: Running/Pulling and Seating Approved By: Vaughan Cullen

Casing and the Start of the hole-Haul Plug Revision Date: 11th Oct. 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK

SCORE

22 Lower last rod to a safe; area i.e.; (Ground or rod sloop) to undo shoe bit using correct stilson use.

Personal injury 21

High

Follow correct manual handling procedures Follow good housekeeping policies SWP SURGEN 2.13 Main Winch Operation SWP SURGEN 2,19 Stilson Use Read MSDS on Chemicals used Gloves Never loosen the shoe bit while working at heights

Never clamp the shoe bit as it will break the diamonds and squash the shoe.

7 Moderate

WARNING

203



Title: Lower Core barrel & Rods Approved By: Vaughan Cullen Revision Date: 11th Oct. 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK

SCORE

1 Make up core barrel ready to run in hole. Personal injury. Lifting. Hand tools

8 Moderate

Correct use of hand tools. Correct manual handling. SWP SURHSE1.02 Manual Handling Check bit, stabilizer/s, landing ring and gauge reamers. Ensure all joins are correctly made up. Check length of inner tube and adjust as necessary, Check condition of backend and tubes, replace as necessary.

4 Low

2 Hoist barrel up the mast, check length of tube. And lower in to foot clamps.

Personal injury. Struck by moving parts. Drop barrel and or rods.

8 Moderate

Refer to SVVP SURGEN2.13 Main Winch Operation UDR 550,1000,12000. At no time shall any body part come between the moving rod and any stationary object. Ensure winch rope and hoisting plug and threads on sub are in good condition. (Tube length will depend on bit type and ground). Ensure barrel is secure in foot clamps before un screwing hoisting plug. Ensure toe guard is in place. -

3 Low

3 Connect next rod to hoisting plug and winch up mast.

Personal injury. Manual handling.

8 Moderate

Refer to SWPSURDIA 5.11 Running/Pulling Rods. Rods to be checked for belled or damaged threads. Threads to be cleaned with wire brush. Pin end greased with thread grease. Box end lightly oiled. Rods shall be counted and the number recorded before lowering into hole. Ensure hoisting plug is made up hand tight in next rod. Driller to watch box end of rod and offsider to control pin end as it is pulled off the rod rack. SWP SURHSE 1.02 Manual Handling

3 Low

4 Lower pin end of rod into box end that is in the toot clamps and make up to correct torque

Personal injury. Pinch. 8

Moderate

Offsider to guide pin into box end. At no time shall any body part come between the moving rod and any stationary object. Correct use of stilsons SWP SURGEN 2.19 Stilson Use

3 Low

5 Lower rod string until box end is 20cm above toot clamps.

Equipment damage. 8

Moderate Driller takes the weight on the winch and open the foot clamps. Lower drill string. Slow down as box end nears foot clamps.

3 Low

204



Title: Lower Core barrel & Rods Approved By: Vaughan Cullen Revision Date: 11th Oct. 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK

SCORE

6 Close foot clamps Personal injury. Pinch 18

Moderate

Offsider shall be clear of the area of the feet clamps. Ensure drill string is secure in feet clamps before slackening winch rope. Offsider unscrews hoisting plug.

10 Moderate

7 Follow steps 3-6 until the required number of rods have been run in the hole

Rods shall be counted and the number recorded before lowering into hole.

205



Title: Setting Hold Back – Pull Down – Micro Feed Approved By: Vaughan Cullen Revision Date: 11th Oct. 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK

SCORE

Step 1 —Setting the hold back

1 Run motor at 1200 to 1500 rpm

2 Decrease pull down control to zero

3 Increase fully the micro feed speed control

4 Rotate the rods slowly with drilling fluid — or air when RC drilling —- circulating at medium speed

Personal injury ·- spinning rods

Whipping rods

24 high

Close safety guard Engage rod whip guard

7 Moderate

5 Engage micro feed lever "down"

6 Adjust the hold back so that the rotation head stops creeping down. Do not over adjust the hold back

Step 2 — Adjust pull down and micro feed

7 Hold rods with hydraulic clamp or rod spanner

8 Engage micro feed lever "down"

9 Increase micro feed speed control

10 Increase pull down pressure by adjusting pull down control until desired weight on the bit is obtained on the pull down gauge.

Exceeded pull down pressure The 6m bead rod buckles or breaks

24 high

Do not exceed pull down pressure. Refer to pull down chart in UDR manual.

7 Moderate

11

When drilling, control the rate of penetration by adjusting the micro feed speed control. lf more pull down is required for stripping a bit etc. Do not exceed the maximum allowable pull down as shown on the maximum allowable pull down chart in the UDR manual.

206



Title: Setting Rotation Approved By: Vaughan Cullen Revision Date: 11th Oct. 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK

SCORE

1 Select rod whip guard "ON" Persona! injury — rod whip 24

High Engage whip guard and check kelly rod is straight

7 Moderate

2 Push high-low gear selection lever into high gear (3:1 ration)

3

Adding Rods First set the engine throttle at 2200 rpm, fully engage the slow rotation lever then use the slow rotation speed control to set the spindle at a safe speed of say 30rpm

Personal injury — rod breakage

ALWAYS USE THE SLOW ROTATION LEVER WHEN ADDING RODS, NEVER USE THE MAIN ROTATION LEVER AS IT IS TOO TOUCHY AND COULD RESULT IN SERIOUS INJURY IF THE ROTATION GETS OUT OF CONTROL! ENSURE THE SLOW ROTATION SPEED IS SET NO HIGHER THAN 30 RPM

4 When adding a drill rod ("making" the joint with the rotation head) ensure the MAIN PRESSURE does not exceed 180 bar

5 When ready to drill run the diesel engine at maximum speed

6 Start bean pump and ensure that fluid is circulating.

Burning in the bit. 18

Moderate Ensure drilling fluid is circulating around the bit before starting rotation.

9 Moderate

7 Close spin guard. Personal injury – spinning rods 23

high Close safety cage when rods are spinning Do not wear loose clothing

4 Low

8 Engage the main rotation lever and move it firmly to the full forward speed setting

Incorrect rotation speed. 18

Moderate Control rotation speed by use of the pump stroke / de-stroke lever

9 Lower the bit slowly onto bottom and start drilling

207



Title: Diamond Drilling Approved By: Vaughan Cullen Revision Date: 11th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK

SCORE

1 Ensure inner tube is latched into the barrel.

Equipment Damage Personal injury hit by moving object.

Miss latch, core in barrel, rod pull.

7 Moderate

Inspect equipment prior to use. Never try and catch any falling item

2 Adjust circulation pump speed. Ensure mud has been mixed as required and pump is running smoothly.

3 Lower rods to 10cm off bottom Damage to bit. 7

Moderate Reference mark on rods to indicate where bottom is.

2 Low

4

Increase rotation speed, feed bit to bottom of hole.

Rotating equipment. 24

High

Ensure spin guard is in place and closed before starting rotation. Ensure that rotation cut off mechanism is in working order e.g. test prior to commencing drill operations rotate rods slowly open spin cage gate rotation should stop if not close rig down and notify supervisor. Feed bit slowly, be aware that there may be core or cave in on the bottom of the hole.

7

5 On bottom, cutting new ground. Core loss, burnt bit, stuck rods. 21

High

Closely monitor water pressure, bit weight and torque. Increasing water pressure may indicate core has blocked off in the tube. Sudden loss of water pressure could indicate broken rod. If a loss of water return occurs at the same time the bit may have drilled into a cavity or an area of lost water return. Record all the hole depth of lost water return, cavities, cave in, swelling or problem ground.

5 Low

6 Continue to monitor all parameters until end of core run.

Core loss, burnt bit, stuck rods. 21

High Stop at end of run as measured or if core blocks off.

5 Low

7 Stopping the run. Damage to bit. Spinning rods off.

4 Low

Pull the head back just far enough to take the weight off the bit but not so far as to break the core. (This will depend on the depth of the hole and drill string size.) Reduce rotation speed to a smooth stop. Mark the rod to show where the bottom of the hole is and measure the stick up.

1 Low

8 Rod Breaking 14 Pull the head back to break the core whilst water pump 2

WARNING

208



Title: Diamond Drilling Approved By: Vaughan Cullen Revision Date: 11th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK

SCORE

Break the core

Moderate

is on and note if sudden loss of water pressure to indicate broken rod. Never run an overshot through a broken rod string.

Low

9 Pull the inner tube. SWP SURDIA 5.07 Seat Tube

WARNING

209



Title: Use of Power Stilsons Approved By: Vaughan Cullen Revision Date: 11th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK

SCORE

1 Do Pre Start

Personal injury trip, fall hit by moving object inability to identify hazardous conditions without proper assessment

12 Moderate

PPE to be worn at all times Hard Hat, steel capped boots, Safety glasses, hearing protection, gloves, Trousers and long sleeve shirt.

5 Low

2 Pull rods back to position where join is between clamps and breakouts.

Equipment damage Damage to stilson, hooks heels, cylinder rod, squash drill rods.

21 High

Ensure Driller's Assistant has clear understanding of stilson use. Ensure clamps are closed before placement of stilsons.

8 Low

3 Close clamps take weight off rods by lowering head slightly or lowering winch rope slightly.

Personal injury. Pinch, crush points to hands, limbs and fingers. Struck by moving parts unexpected or uncontrolled movements.

Equipment damage.

17 Moderate

At no time shall any body part come between the rod and foot clamp jaws. Make sure clamps are holding correctly and not slipping. Ensure correct size slips are being used.

8 Low

4 Adjust power stilson to the correct size and place on the rod.

Personal injury. Pinch, crush points to hands, limbs and fingers.

Struck by moving parts unexpected or uncontrolled movements.

Equipment damage Damage to stilson hooks heels, cylinder rod, squash drill rods.

17 Moderate

Ensure stilsons are opened correctly to suit the size of rod being broken. Be aware of pinch points. Wear gloves. Follow SWP SURGEN249 correct stilson use.

4 Low

210



Title: Use of Power Stilsons Approved By: Vaughan Cullen Revision Date: 11th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK

SCORE

5 Take up pressure on rod with the power stilsons. Break the join.

Personal injury. Pinch, crush points to hands, limbs and fingers.


Equipment damage. Damage to stilson hooks heels, cylinder rod, squash drill rods.

21 High

Using control lever take up pressure on rod Once the pressure has been taken up by the power stilsons, the driller’s assistant takes his hands out of the way. Driller must be sure the assistant is clear before proceeding to break rod join with power stilsons.

5 Low

6 Reposition the rods and power stilsons

Personal injury. Pinch, crush points to hands, limbs and lingers.


Equipment damage Damage to stilson hooks heels, cylinder rod, squash drill rods.

17 Moderate

lf for any reason rods have to be repositioned in the hole, take the power stilsons off the rods and take up slack on winch or head before moving rods, Driller shall not move lever controls for power stilsons while assistant is moving them out of the way.

5 Low

211



Title: Core Tube Recovery Approved By: Vaughan Cullen Revision Date: 11th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK

SCORE

1 Stop Rotation End of core run or when core "blocks off".

Pulling back to far, breaking the core. Stopping rotation too quickly possibly causing rods too back spin or undo.

18 Moderate

Pull the head back just far enough to take the weight off the bit but not so far as to break the core. (This will depend on the depth of the hole and drill string size.) Slow rotation speed to a smooth stop Mark the rod to show where the bottom of the hole is and measure the stick up.

5 Low

2 Pull the drill string back and feel for the core to break

Core lifter not gripping, leaving core clown the hole. Rod breaking

18 Moderate

If the core break is not felt, feed the bit back to bottom. Pull the rod string back again quicker to get the lifter to grab Leave water pump engaged to note water pressure loss and possible rod breakage. In hard ground and large amounts of pullback are required to break core. Pullback and shut water off, vent and core will break with a "pop". Engage water pump and note water pressure.

5 Low

3

Set drill string in foot clamps to break out the head or pull rods back to 3m, or 6m join and set in foot clamps. Turn off water pump

Personal injury, crush. 21

High Ensure Drill Assistant is clear before closing foot clamps.

14 Moderate

4 Vent water. Break out join.

Personal injury hands. Hand injury use of power stilsons Eye injury from water not vented.

21 High

Vent excess water pressure. Use slow rotation to break out join or correctly use break out tool. SWP SURGEN 2.19 Stilson Use SWP SURGEN 2.20 Using Breakouts PPE: Gloves and Eye protection

14 Moderate

5 Run head up the mast and retract or slide to the side.

Equipment damage. Winch rope, wire line.

21 High

Ensure that the winch rope and wire line do not become caught by the rotation head. Ensure pulley are serviceable and moveable parts are greased regularly. Pre-start inspections

9 Moderate

WARNING

212







RESIDUAL RISK

SCORE

6 Lower over shot into open drill string Personal hands. Over shot not picking up the tube.

18 Moderate

Ensure lifting dogs are in good condition, Wear gloves, watch for potential pinch points as over shot is lowered into rods. Lower over shot, slow as it nears the bottom of the hole. Listen for over shot landing on top of inner tube. Refer to SWR SURGEN 2.14 Wireline Winch Operation

13 Moderate

7 Recover over shot and inner tube

Personal injury. Equipment damage. Broken wire line. Tube falling off over shot.

21 High

lf applicable to rig note the wireline torque limiter setting, Pull up slowly. Noting increase in main pump pressure. Pull tube at maximum of 100 bar on main pump pressure until the over shot is near the foot clamps (This can be determined by marks on the wire line, an increased amount of water discharged from the rods.) Slow the pulling speed as the over shot appears through the rods. Pull the wireline up until the over shot and backend are clear of the rod and engage safety lock. Pull tube clear of the rods. Offsider to guide the lower end of tube out of the rods and place it on the rod rack. Never stand under the suspended inner tube.

9 Moderate

8 Remove over shot from full tube and latch onto empty tube. Engage safety lock.

Personal injury hands. 12

Moderate Wear gloves. Ensure lifting dogs and back end spear are in a good condition. ·

5 Low

9 Hoist empty inner tube up the mast.

Personal injury. Equipment damage, tube falling off over shot.

21 High

Offsider shall control the lifter end of the tube and guide it into the open end of the rod. Disengage safety lock once backend is about to enter rod. Never stand under the suspended inner tube.

9 Moderate

10 Lower inner tube into the rods and release.

Dropping tube into dry hole.

18 Moderate

Release the inner tube; ensure the spear end remains up right. Do not drop tube into “dry" hole. If water level is a long way down, pump water into hole before dropping tube, or use dry release and lower tube with wire line. Overshot can then be released once tube hits water or is latched into barrel.

9 Moderate

WARNING

WARNING

WARNING

213







RESIDUAL RISK

SCORE

11 Add rod. Personal injury. 18

Moderate SWP SURGEN 5.17 Adding/Removing a rod with Clamshell

9 Moderate

12 Couple up rotation head. Start circulation pump.

Personal injury hands. Equipment damage.

21 High

Drillers Assistant to guide rods or spindle into box end of rod in foot clam s. Wear gloves keep hands clear of threads.

14 Moderate

13 Pump tube down until seated in the core barrel.

Tube not seating in the barrel.

18 Moderate

Note the time taken to pump the tube down. As the tube nears the bottom as indicated by the time, ensure rotation is in neutral. Place stilson on the rods and listen for the tube to land. (There should be a double click and an increase in water pressure.) lf you don't feel the tube land or the pump pressure doesn’t come up, then jerk the rod string until the pressure rises. If tube doesn‘t land within a minute or so of expected time then you need to do something about it. (i.e. pull the tube again) Do not start drilling if you are unsure if the tube is seated.

9 Moderate

14 Lower rods to within 10cm of bottom and start next run

Personal injury. Rotating equipment.

24 High

Ensure all personnel are clear of rods and the spin guard is locked closed before starting rotation.

6 Low

WARNING

WARNING

214



Title: Empty Core Tubes and Wash Core Rock Approved By: Vaughan Cullen Revision Date: 11th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK

SCORE

1

Mark up core tray. As per clients instructions or Mark tray with hole number, rig number tray number Write "Start" at top right corner of tray as you look at it while emptying the tube.

Hand injury from sharp edges of tray. Incorrect mark up of tray.

16 Moderate

Wear correct PPE — gloves. Follow client instructions for correct mark up of tray. . Place empty core tray on racks suitable for the weight of core and to minimize manual handling of crew and client. Ensure legible writing Ensure tray is clean of contain aments.

3 Low

2 Place core tube Assembly on the core tube racks.

Hand crushed between tube and racks.

16 Moderate

Correct manual handling. Wear gloves, hold tube at the ends or near the middle. Avoid placing hands between tube and racks Gloves to be worn

8 Moderate

3 Break out and remove back end. Pinch points. Equipment damage.

11 Moderate

Use correct size tube wrenches. Place back end on the tube rack. Take care not to damage threads. SWP SURDIA 5.22 Assemble Tube

2 Low

4 Screw thread protector on to tubes. Personal injury. Hands. 12

Moderate Wear correct PPE — gloves

5 Low

5 Measure core. Core loss or core left down the hole.

18 Moderate

Place tape measure into tube and measure from the thread protector to the core. Report measurement to driller. Check amount of core in the tube matches the length of the core run. Report any core loss.

8 Moderate

6

Move tube into position so open end is down over the core tray and lifter end is elevated. KEEP HANDS CLEAR OF END OF TUBE.

Personal injury. Hands. 20

Moderate

Never place hands over the open of the tube. Core can be sharp and slide out of the tube unexpectedly. Gloves

KEEP HANDS CLEAR OF END OF TUBE

8 Moderate

WARNING

215







RESIDUAL RISK

SCORE

7 Remove core and lay out in the tray. Personal injury. Back. Core does not slide out of tube.

20 Moderate

Stand astride the tube, knees bent, use smooth back and forth motion to slide core out of the tube. Do not handle core with dirty hands or dirty gloves. Core to be laid out from top right to bottom left as looked at from the position you are in as the tube is emptied. Follow client's instructions as to marking of deliberate core breaks, core blocks and mark up of core trays. Use dead blow hammer to strike the tube to loosen jammed core. Never strike tube with steel hammer. If core will not come out of the tube, turn tube around and remove core lifter. Empty core into anther tray. If core is still stuck in tube a steel bar can be slid into the tube to assist with removal of the core. The core will need to be turned around and place correctly in the tray. Place core in tray so it is as representative as practicable of how the core entered the tube.

8 Moderate

8

Empty the last piece of core. LOOK DOWN THE TUBE NOT UP.

Personal injury. 16

Significant

When all the core is out of the tube visually check. Look down the tube never up. The last piece of core could be stuck in the core litter. If core is protruding out of the core lifter, it can be loosened by striking the core against a wooden block. If a hammer is used place a piece of rag over the core to prevent broken fragments of rock flying around.

5 Low

9 Replace the tube on the tube racks. Check core lifter.

Core lifter not gripping core correctly.

12 Moderate

Wash out any clay, sand or rock fragments. Clean core lifter and use a piece of core to check the core litter is gripping the core. Ensure the core litter is tight on the tube. Lubricate core lifter with a little AMC universal / bit lube.

5 Low

WARNING

216







RESIDUAL RISK

SCORE

10 Fit back end.

Back end unscrewing down the hole. Shut off valves and or bearings worn. Water ways and or ball valve blocked.

12 Moderate

Clean threads; apply a small amount of grease to the threads. Tighten the back end using correct size tube spanners. Grease back end bearings, wipe off any excess. Check bearings, shutoff valves for wear. Check water ways and ball valve are clear. Check condition of spear head, detent base and roll ins.

5 Low

11 Mark core block and place in tray. Wash Core.

Poor core presentation. Incorrect measurements.

20 Moderate

Wash core with water and detergent. Ensuring all marks are removed and the core interlocks with previous piece. Mark all crew core breaks with a small cross using a red orientation pencil. Drillers to collaborate run sheet book with core block and place in tray at end of run, noting any loss of core orientations etc. Mark hole depth on core tray at the end of the core were the core block is positioned.

5 Low

217







RESIDUAL RISK

SCORE

Adding New Tool Joints to the Drill String Experience shows that the first few trips in the holes area are the most hazardous in the life of rod tool joints. For this reason, extra care must be taken during the break-in period. We recommend the following steps for handling new tool joints. 1. Keep threads on the water swivel and the hoisting plug in good

condition, as they mate with every box.

2. Thoroughly clean pin heads, box threads and shoulders. When you run Boart Longyear rods into the hole, liberally coat the pin and box threads and shoulders with Esso Z-50 recommended thread grease.

3. Before each trip, coat the box threads and shoulders with the lubricant again.

4. Avoid forced makeup of improperly engaged threads. In stabbing, the flat crests on new threads sometimes wedge against each other. A slight amount of back up will free them.

Removing Core from the Inner Tube

1. Unscrew the inner tube from the head assembly, using Boart Longyear tube wrenches (Figure 4D). When you use two inner tubes, inspect and service one, between core runs, while the other one is inserted into the drill string and pumped into position.

2. Empty core from the inner tube. Jar the core loose from the inner tube by tapping with a rubber mallet (Figure 4E). Place the core carefully in a box and mark as instructed by the geologist on site.

When emptying the inner tube, do not attempt to stop the core with your hand. Core can be sharp or heavy and cause severe injury. If it’s necessary to look into an inner tube, always look down into the tube.

3. Between each core run, check the inside of the inner tube to be sure all the core has been removed. Flush out the inner tube with clear water to remove all chips and grit.

4. Check the core filter case, stop ring, and core lifter (Figure 4F). The core lifter should rotate freely. If the inside surface of the core lifter is smooth, the grip action on the core lifter should be checked. Insert a short section of core into the core lifter and pull it out to see if the core lifter will firmly grip the core. If the core slips, replace the core lifter (See chapter 6: Inspection and Maintenance – After Service).

5. Lightly grease the outside of the core lifter and the inside of the core lifter case.

218



Title: Pumping out Splits & Approved By: Vaughan Cullen

Removing Core from Q3 Inner Tube Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK

SCORE

1 Set up trestles in safe working area. Lifting, personal injury. 20

High

Safe manual handling procedures, set trestles up so tube can be safely handled with the wire line. SWP SURHSE 1.02 Manual Handling

5 Low

2 Lay inner tube on trestles. Heavy lifting. Personal Injury

16 Moderate

Safe manual handling procedures Train and Assess employees to this instructions

4 Low

3 Remove back end place on rack. Personal injury - hand tools 16

Moderate

Correct use of hand tools. Reset one wrench on solid surface and use both hands to apply pressure to second wrench. Make sure you are well balanced.

4 Low

4 Remove core litter. Personal injury — hand tools. Core jammed in lifter.

11 Moderate

Correct use of hand tools. Reset one wrench on solid surface and use both hands to apply pressure to second wrench. Make sure you are well balanced.

5 Low

6 Screw piston plug into pump out piston. Hand injury on sharp thread end of inner tube.

11 Moderate

Wear protective gloves. 2

Low

7 Screw pump out adaptor with pressure hose attached onto inner tube.

Equipment damage cross threading adaptor and tube.

7 Moderate

Ensure threads are clean. Start screwing slowly. 2

Low

8 Start fluid pump slowly so the piston pushes the split tubes out in a safe controlled.

Fluid pressure builds up. Splits shooting out fast. Personal injury.

16 Moderate

Stand on either side of inner tube, not in front. Control pump out pressure.

HIGH PUMP PRESSURES

4 Low

9 When split tubes are out, remove piston and clean.

10 Carefully remove the top split. The top split may stick to the core. Unable to remove top split.

4 Low

Try to slide rather than lift the top split off. 2

Low

WARNING

219



Title: Pumping out Splits & Approved By: Vaughan Cullen

Removing Core from Q3 Inner Tube Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK

SCORE

11 Measure core in split Core loss not recorded Measure core in split. Check driller’s run sheet. Record any core loss.

12

Place the piston end of the split containing core into the tray next to the previous core then slide the core into the tray with care as the split is pulled slowly back.

Personal injury, sprains and strains lifting.

18 Moderate

13 Remove core from core lifter case and, place core in the tray.

Personal injury hands. Cuts bruise.

12 Moderate

Wear gloves, take care if you have to use a hammer to tap the core out. Eye protection

2 Low

220



Title: Correct Core Presentation Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK

SCORE

1

Mark up core tray. As per clients instructions or Mark tray with hole number, rig number tray number. Write "Start" at top right corner of tray as you look at it while emptying the tube.

Hand injury from sharp edges of tray. Incorrect mark up of tray.

16 Moderate

Wear correct PPE — gloves. Follow client instructions for correct mark up of tray. Ensure legible writing Ensure tray is clean of contaminants.

3 Low

2 Place empty core tray on racks in a serviceable area.

Personal injury beware of sharp edges on core trays and actual core

11 Moderate

Apply safe manual handling procedures Place empty core tray on racks suitable for the weight of core and to minimize manual handling of crew and client. SWP SURHSE 1.03 Housekeeping Work Area

4 Low

3

Before placing core in the tray, measure length of core in splits, or if core is in inner tube measure the distance from the end of the core to the end of the tube. Check length of core run and tell driller how much core is in tube or splits to find whether core has been lost.

Incorrect core measurement. 20

Moderate Measure whole length of core if in splits.

7 Low

4 Lay core in core tray in a neat and organised fashion filling each row from "Start" to end.

Personal Injury – Back 16

Moderate Safe manual handling

4 Low

5

Break core at end of each row, unless instructed by the client otherwise. Mark "driller breaks" as instructed by client or with small cross using a red orientation pencil.

Eye Injury Hand Injury

16 Moderate

Wear protective glasses, Wear protective gloves.

4 Low

6

lf small parts of core falling out of the tube or splits, are not landing in the appropriate row of the tray, pick it up straight away and put it in the proper place. Do not throw core away.

Incorrect core presentation. Not meeting the client’s requirements.

12 Moderate

Place core in the tray the same way it came out of the tube. Place core in tray so it is as representative as practicable of how the core entered the tube.

7 Wash all core with water and

221



Title: Correct Core Presentation Approved By: Vaughan Cullen

Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK

SCORE

detergent, removing all marks

8 Rearrange core to ensure it is representative as practicable of how it entered the core tube, interlocking each piece.

Greasy dirty gloves, grease dirt on core.

7 Moderate

Protective gloves must be free from grease when handling core. 4

Low

9 Should there be any core loss. Incorrect core measurement. 12

Moderate

Driller to collaborate run book with core block, noting any core loss, orientations etc. on the core block and placing at the end of the core run.

4 Low

10 Write correct hole depth on core marker and place at the end of the core run.

Incorrect core measurement. 12

Moderate

Driller to collaborate run book with core block, noting any core loss, orientations etc. on the core block and placing at the end of the core run.

4 Low

11 When core tray is full, place lid on tray if required and put another empty on one top of the full one.

Hand Injury from sharp edges on core tray. Dirt on core from tray.

7 Moderate

Wear protective gloves. Ensure tray is clean before placing on top of lower tray.

4 Low

12 Continue as from step one.

13 Do not put too many core trays on top of each other as the can tall over.

Damage to core trays Loss of core.

16 Moderate

Stack in an orderly fashion Stack in a clean area

4 Low

14 lf instructed to move the full core trays to the core shed, secure trays as specified by the client.

Heavy lifting, back injury Hand Injuries.

20 high

Safe manual handling procedure. Two man lift. Wear protective gloves. SWP SURHSE 1.02 Manual Handling.

7 Low

222



Title: Pulling and Running Rods with Haul Plug Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK

SCORE

1 Break join at foot clamp level Personal injury — hands, arms 20

High Correct use of stilsons SWP SURGEN 2.19 Stilson Use

8 Moderate

2 Remove head rod, if necessary and place on rod rack

Personal injury — lifting 17

Moderate

Use clamshell to remove 6m rods, follow safe manual handling procedures SWP SURQA 5.17 Add/Remove Rod With Clamshell

4 Low

3 Place head plate on head and traverse up fully and rack back. Engage plug slide out to required distance.

Personal injury — rods falling 22

High Never attempt to pull rods over head not racked back.

8 Moderate

4 Screw pulling plug into rod and connect winch cable

Personal injury — back strain 17

Moderate

Follow safe manual handling procedures Pre-start Inspection Check lifting equipment for condition, rating, fatigue, broken wires, birds nesting, kinks from over running on the drum, sound of the winch, sloppy levers etc., At no time shall any body part come between the moving rod and any stationary object. Ensure winch rope and hoisting plug and threads on sub are in good condition. Ensure clevis pin is in good condition SWP SURGEN 2.13 Main Winch Operation

4 Low

5

Take weight with winch and open foot clamps by gently taking the slack on the rope and opening the clamps not skull dragging the rod through the clamps.

Personal injury - cable breaks 22

High

Stand clear when cable is under load At no time shall any body part come between the moving rod and any stationary object. Do not reef on the winch rope as you take the weight and open the clamps Ensure clevis pin is secure

8 Moderate

6 Pull back rods 9 — 12 metres to join and lock in foot clamps

Winch over running on the drum. Rod and winch caught in the head. Equipment damage

22 High

Ensure toe guard is in place Offsider shall be clear of the area of the foot clamps. Ensure that you watch the haul sub go over the head and the winch is spooling correctly Ease off on the winch rope speed as the join comes through the clamps. Ensure drill string is secure in foot clamps before slackening.

8 Moderate

223







RESIDUAL RISK

SCORE

winch rope. PPE

7 Release weight from winch cable

8 Break thread with Stilsons, Safety spin or Auto Breakout

Personal injury – hand tools 20

High

Pre-start inspection Correct use of stilsons Correct lifting procedures SWP SURGEN 2.19 Stilson Use SWP SURGEN 2.20 Using Breakouts

9 Undo thread Personal injury – hands 20

High

lf unscrewing the rod by hand the driller must ensure the rod is held central in the mast by working the winch, that the rig is level, mast is at the angle of the hole and that gloves are worn. UDR 1000 and 1200 rig where the rod spinner is not used ensure the foot plate is inserted so the offsider can place their right foot on the foot plate and left on the deck, maintain a straight back, hands positioned at a comfortable distance apart and then unscrew the rod. If the rod is tight they must stop and use stilsons. Note: This is a one person job carried out by the drillers offsider. UDR650 where a foot plate is not applicable the offsider must stand at a comfortable distance from the rod with feet apart, a straight back ,hands positioned at a comfortable distance apart and then unscrew the rod. lf the rod is tight they must stop and use stilsons. Note: This is a one person job carried out by the drillers offsider. If using a rod spinner and the rod needs to be manually unscrewed follow steps for UDR 650 to remove rod. Follow correct manual handling procedures SWP SURHSE 1.02 Manual Handling on lifting and rod handling equipment.

WARNING

224







RESIDUAL RISK

SCORE

10 Lift rod slightly with winch

11 Offsider directs rod onto rod rack Personal injury – hands 16

Moderate

Never place fingers inside rods or position your hand lower

then 300mm from the top of the pin. Gloves Follow correct manual handling procedures Maintain good communication Ensure good balance Follow good housekeeping policies

4 Low

12 Lower rod Personal injury – rod falls Equipment Damage

16 Moderate

Never stand under suspended load. Lower at controlled speed. Once the rod in on the rack/sloop ensure all crew are in a safe position. Watch the haul plug/winch as the rod comes down the mast to ensure correct positioning and lifting gear is tight/in place.

4 Low

13 Unscrew pulling plug and screw into next rod Personal injury – hands 16

Moderate

Insure all pressure in rod string is released before attempting to remove pulling plug. Monitor condition of the subs and lifting gear

4 Low


15 Check barrel bit reamer etc. and reassemble as necessary. Check drilling tool.

WARNING

225







RESIDUAL RISK

SCORE

16 Run barrel or drilling tool back into hole and grip in foot clamps

Personal injury – hands 20

High

Insure all pressure in rod string is released before attempting to remove pulling plug. Ensure toe guard is in place. SWP SURDIA 5.02 Lower Core Barrel Follow correct manual handling procedures

7 Low

17 Check, clean and grease all rod threads

Rods to be checked for belled or damaged threads. Threads to be cleaned with wire brush. Pin end greased with thread grease. Box end lightly oiled. Rods shall be counted and the number recorded before lowering into hole. Ensure hoisting plug is made up hand tight in next rod. Driller to watch box end of rod and offsider to control pin end as it is pulled off the rod rack. SWP SURHSE 1.02 Manual Handling

18

A: Unscrew pulling plug from barrel and lift winch clear of the mast area B: Unscrew pulling plug and continue as per step 20

19 Lower tube into the barrel Personal injury – hands 20

High

Offsider shall control the lifter end of the tube and guide it into the open end of the rod. Remove safety hook once backend is about to enter barrel. Never stand under the suspended inner tube. Release the inner tube; ensure the spear end remains up right. Do not drop the tube use the dry release and lower tube with wire line. Overshot can then be released once tube is latched into barrel. Remove overshot from the mast area Gloves

7 Moderate

226







RESIDUAL RISK

SCORE

20 Raise rod with winch and connect to barrel/drilling tool

Personal injury 21

High

Raise rod at controlled speed easing off on the lever as the

rod pin nears the end of the sloop/rack. Never stand under suspended load.

Maintain good communication Ensure good balance of the offsider as the rod approaches

Watch the haul plug at least until it clears the head and monitor the spooling on the drum

Follow correct manual handling procedures Follow good housekeeping policies SWP SURGEN 2.13 Main Winch Operation Gloves

7 Moderate

21 Tighten threads with stilsons or safe- t—spin Personal injury – tool slips 16

Moderate

lf screwing the rod by hand the driller must ensure the rod is held central in the mast by working the winch, that the rig is level, mast is at the angle of the hole and that gloves are worn. UDR 1000 and 1200 rig where the rod spinner is not used ensure the foot plate is inserted so the offsider can place their right foot on the foot plate and left on the deck, maintain a straight back, hands positioned at a comfortable distance apart and then screw the rod. If the rod is tight or cross threaded they must stop and use stilsons.

4 Low

WARNING

WARNING

227







RESIDUAL RISK

SCORE

UDR650 where a foot plate is not applicable the offsider must stand at a comfortable distance from the rod with feet apart, a straight back ,hands positioned at a comfortable distance apart and then screw the rod. lf the rod is tight they must stop and use stilsons. lf using a rod spinner and the rod needs to be manually unscrewed follow steps for UDR 650 to remove rod. Follow correct manual handling procedures SWP SURHSE 1.02 Manual Handling Pre—start inspections on lifting and rod handling equipment. Correct stilson use SWP SURGEN 2.19 Stilson Use

22 Repeat steps 15 to 20 until all rods are back in hole

23 Reconnect rods to heed

228

STANDARD WORK PROCEDURE No: SURDIA5.12 Prepared By: Vaughan Cullen

Title: Pulling and Running Rods Using Approved By: Vaughan Cullen

Rod Stacking Bar – Rods in Mast (3) Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Break join at foot clamp level Personal injury – hands, arms 20 High

Correct use of Stilsons Train and assess employees to this work instruction.

2 Remove head rod, if necessary and place on rod rack

Personal injury – lifting 21 High

Use clamshell to remove 6m rods, follow sale manual handling procedures Train and assess employees to this work instruction.

7 Moderate

3 Fit clevis pin to winch rope hauling plug, making sure split pin is secure. Visually inspect pin before inserting in plug.


Moderate

4 Run head up and rack back or out fully Personal injury – rods falling 22

High Never attempt to pull rods over head

8 Moderate

5 Screw pulling plug into rod and connect winch cable.

Personal injury – back strain 13

moderate Follow safe manual handling procedures Train and assess employees to this work instruction.

4 Low

6 Take weight with winch and open foot clamps Personal injury – cable breaks 19 moderate

Stand clear when cable is under load. 8 Moderate

7 Pull back rods 9 – 12 metres to joint and lock in foot clamps

8 Release weight from winch cable

9 Break thread with Stilsons, Safety spin or Auto Breakout

Personal injury – hand tools 20

High Correct use of Stilsons Train and assess employees to this work instruction.

4 Low

10 Undo thread

11 Lift rod slightly with winch

12 Driller lowers rod onto drill platform Personal injury – hands, feet 21

High

Never place lingers inside rods Lower at controlled speed. Never stand under load.

7 Moderate

13 Drill helper directs rod into "V" slide Personal injury – rod falls 21

High Never stand under suspended load, lower at controlled speed.

14 Visually inspect pin before unscrewing pulling plug and place on mast slide for lowering.


moderate Insure all pressure in rod string is released before attempting to remove pulling plug.

4 Low

15 Drill assistant places rod into rod stacking bar.


High Correct position of drill rod. Rod falls

4 Low

229


Title: Pulling and Running Rods Using Approved By: Vaughan Cullen

Rod Stacking Bar – Rods in Mast (3) Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

16 Driller lowers plug on winch cable - screws into next rod for hoisting & visually inspect split pin holding clevis’ pin


Moderate Lower at controlled speed & if split pin damaged, replace

4 Low


18 Check barrel bit reamer etc. and reassemble as necessary.

19 Run barrel back into hole and grip in foot clamps


High Ensure all pressure in rod string is released before attempting to remove pulling plug.

4 Low

20 Check, clean and grease all rod threads

21 Unscrew pulling plug from barrel and screw into rod on rack

22 Raise rod with winch and connect to barrel Personal injury 17

Moderate Raise rod at controlled speed. Never stand under suspended load.

4 Low

23 Tighten threads with Stilsons or safe-t—spin Personal injury – tool slips 20

High Correct Stilsons use Train and assess employees to this work instruction.

4 Low

24 Repeat steps 18 to 21 until all rods are back in hole

25 Reconnect rods to head

26

Remove hauling plug from winch rope. Clean & inspect. Leave in container until next rod trip where a new split pin will be placed in clevis pin


Moderate Insure hands are clear of pinch points on hammer lock

4 Low

230



Title: Rod Vibrations – Dry Hole and Bent Rods Approved By: Vaughan Cullen

(Note: SURDIA5.13 replaces SURDIA5.14 Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Pull rod string. Personal Injury 20

High

As per SWPSURDIA 5.11 Pull/Run Rods Haul Plug Correct us of hand tools. Ensure safe working area as per Train and assess on these written work instruction.

7 Moderate

2 Let rods dry before applying grease. Use a rod wipe rubber whilst pulling out

3 Run rods down hole and apply rod grease evenly to each length of rod.

Cut hands on burrs on rods while applying grease.

20 High

Wear protective rubber gloves File off burrs.

7 Moderate

4 Wash down last few stands of rods as there could be sludge in the hole.

5 Continue drilling. Rotating Rods Personal Injury

20 High

Keep clear of rotating rods. Erect barricades/guards SWP SURDIA 5.05 Diamond Drilling

2 Moderate

6 Rods will rotate at higher torque until grease starts wearing off.

231



Title: Rod Vibrations – Dry Hole and Bent Rods Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

7 Pull rods, lay on surface. Personal injury Slipping, Falling

20 High

Correct us of hand tools Ensure safe working area as per Train and assess on these written work instruction. As per SWP SURDIA 5.11 Pull/Run Rods Haul Plug

4 Low

8 Check the first length of drill rod prior to lowering in to drill hole by lying next to a straight drill rod.

Personal Injury, Rod falls on foot

20 High

Safe manual handling procedures Train and assess on these written work instruction.

7 Low

9 If drill rod is bent, break joint on drill rod with Stilsons, unscrew and replace with a straight drill rod.

Injury to Hands 11

Moderate Correct use of hand tools wear protective gloves

4 Low

10 Lower length of drill rod into drill hole and check next length of drill rod. If bent, proceed as in step five.

11 Flush hole before bit will get to bottom of hole,

12 Isolate and tag bent rods. Note why the rods became bent and rectify drilling practices.

232

STANDARD WORK PROCEDURE No: SURDIA5.15 Prepared By Vaughan Cullen

Title: Rod Vibrations – Rig Off Line Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1

Rig may be off line due to hydraulic leak of one or more jack up legs or sinking in soft ground. Check rig alignment with inclinometer

2 Flush hole clean of cuttings.

3 Lift rod string off bottom and rest in hydraulic clamp.

4 Brake rod joint below spindle and unscrew. Personal injury 20

High Correct use of hand tools.

4 Low

5 Lift head slightly above rod string resting in hydraulic clamp.

6 Check which jack up leg needs to be pushed down or up.

Equipment damage — Head may be off set

20 High

Adjust accordingly. 7

Moderate

7 Push jack up leg until spindle lines up with rods resting in hydraulic clamp.

Personal injury and Equipment damage —Jack up leg can slip off timber if timber has sunk uneven. Over jacking can cause rod in clamps to be bent

22 High

Lift up jack leg, straighten timber or remove, level ground and replace timber. Adjust inclination in relation to the alignment of rod

7 Moderate

8 Connect spindle to rod string and circulate drilling fluid.

9 Open clamp and rotate rods. Personal injury — Rotating rods 24

High Keep clear of rotating rods, and fit guard.

2 Low

10 Check for vibration, continue drilling.

11 Lower mast, if one or more lack up legs needs to be raised.

Personal injury Loose objects fall on persons

22 High

Ensure no loose objects are on the mast. 4

Low

233



Title: Rod Vibrations – Rig Off Line Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

12

Rig may have to be realigned with mast down using skids or driving to ensure vibration doesn’t continue. Re-bedding of the jack legs to step sinking.

Rig continuing to sink Hole not lining up

18 Moderate

Criss-cross or pig sty bed logs for a sturdier base. Before lowering mast either: Pull rod string SWP SURDIA Pull/Run Rods 5.11 or rest on bottom of clean hole with tube out of barrel. ADlTC Competencies

4 Low

WARNING

234



Title: Lost Circulation Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 When complete circulation loss occurs do not drill too far ahead before applying Aus-Plug Measure stick up

Pull tube before pouring Aus—plug down hole

2 Sit rod string in clamp and break rod joint Personal injury

17 Moderate

Correct use of hand tools SWP SURGEN 2.19 Stilson Use SWP SURGEN 2.20 Using Breakout Stilsons

7 Moderate

3 Pull tube, and put warning mark on wireline SWP SURDIA 5.07 Seat tube recovery

4 Put a small amount (0.25 — 0.50kg) of Aus-Plug into a 20 Litre container and wet only slightly.

5 Pour the slightly wet Aus—Plug directly down the rods

6 Clean box end of rod and join to spindle

7 Start bean pump

8 With drilling fluid being pumped down hole, lower rod string within approximately 20cm from bottom of hole

Water pressure rises very high. Blocked bit, rotating rods, personal injury.

22 High

Do not pump fluid down too fast, approximately 50 Litres per metre fit safety guard

4 Low

9 Rotate rod string slowly

Rotating rods Personal injury

22 High

Fit safety guard 4

Low

10 When water pressure suddenly rises the lost circulation material is then passing the bit

11 Wait until pressure drops and pull rod string until rod joint is above clamp

WARNING

235



Title: Lost Circulation Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

12 Continue to pump fluid down the hole for a short time to make sure all lost circulation materials has past the bit And out of the barrel.

Water pressure will decrease Should also see a water return if cavity is plugged.

13 Stop pressure pump, break rod joint and lower inner tube on overshot with dry release, if hole is dry, into core barrel

Personal injury Tube comes off overshot Tube will fall down hole

16 Moderate

Correct use of hand tools Careful when lowering tube Correct handling of dry release SWP SURDIA 5.07 Seat Tube Recovery

4 Low

14 Release tube from overshot and pull overshot to surface

Tube not released when pulling overshot

7 Moderate

Watch pressure on torque gauge when start pulling 4

Low

15 Connect spindle to rod string and pump drilling fluid down the hole

16 Lower rod string slowly within 20cm off bottom of hole and rotate rod string.

Rotating rods Personal injury

22 High

Fit safety guard 4

Low

17 Rotate rods to bottom of hole and continue coring

18 Repeat process if fluid return has not improved

236



Title: Adding/Removing 6m Rods with Clamshell Approved By: Vaughan Cullen

Running/Pulling Casing with Clamshell Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

Removing Rods. Check clamshell is not flared

1 Check condition of clamshell cable and hook. Damaged equipment- rod may drop — personal injury.

24 High

Cable is in good condition, cable clamps fitted correctly MAINT 8.005, hook is not badly worn or cracked. Pre—Start Inspections

8 Moderate

2 Pull rods back with head and sit in foot clamps.

3 Break joint at foot clamps, use break out Stilsons if required.

Personal injury 20

High

SWP SURGEN2.20 Using Breakout Stilsons SWP SURGEN2.19 Stilson Use Train and assess employees to this instruction

4 Low

4 Unscrew join using slow reverse rotation Personal injury 20

High Ensure water/air pump is turned off and vented

5

With box and pin joints still together use back up Stilson to crack joint at drive sub. Note: lf 6m join breaks, unscrew and remove rods in 2 x 3m lengths.

Personal injury - lifting -

20 High

Follow correct manual handling procedures SWP SURHSE 1.02 Manual Handling SWP COALGEN 13.02 Use Of Modified Backup Stilsons Use modified back up stilsons Maintain good communication and look at stilson positioning and hand/finger location.

4 Low

6 Ensuring top joint is cracked only, lift head and head rod.

Top join undoes, rod falls personal Injury.

22 High

Check top thread has not undone. Do not stand under / In line with rod.

8 Moderate

7 Slide clamshell over rod and raise with winch several metres

Clamshell grabs, rod kicks out 21

High Never stand in line with rod. Slow smooth lever operation

7 Moderate

8 Place hook in pin end of rod and gently take slack out of cable with winch.

Hook and cable pull too tight rod kicks out.

22 High

Never stand in line with rod. Use head traverse rather than winch to take up last bit of slack for more control. Gloves

8 Moderate

WARNING

WARNING

237



Title: Adding/Removing 6m Rods with Clamshell Approved By: Vaughan Cullen





RESIDUAL RISK SCORE

9 Use slow reverse rotation to undo rod. Lift head whilst rod being unscrewed.

Hook grabs & spins - Personal injury Rod Drops

23 High

Hold hook in left hand with thumb in upright position. lf this grip is maintained and rod kicks hand will be flung clear. Use right hand as a steadier on rod. Only lift head enough to take excessive tension off clamshell rope. Gloves ADlTC Competencies.

8 Moderate

10 Holding hook handle pulls rod onto rod rack. Personal injury 20

High Never place body or hands under suspended load. Ensure hook stays inside rod pin and rope maintains tension.

4 Low

11 Running the rod/s onto a rod sloop or rod truck that requires offsider to be on truck

Slips Falls from truck and sloop Personal injury

22 High

Ensure rod sloop is as low to the ground as possible Ensure safety ropes and bars are attached along the side of truck. Work on an even surface Maintain good communication with crew. Ensure smooth lever operation

WARNING

WARNING

238



Title: Adding/Removing 6m Rods with Clamshell Approved By Vaughan Cullen





RESIDUAL RISK SCORE

Adding rods

12 Inspect condition of clamshell cable and hook Damaged equipment- rod may drop — personal injury.

18 Moderate

Check clamshell is not flared, cables in good condition, cable clamps fitted correctly, MAINT 8.005 hook is not badly worn or cracked Pre-start Inspections

7 Moderate

13 Slide clamshell over rod and place hook in pin end of rod.

14 Move clamshell towards box end until cable to hook is tight.

15 Slowly lift rod with winch, drill assistant guiding rod by holding hook.

Hook falls out of rod. Rod catches on something causing it to kick out.

21 High

Ensure connector cable is taught as per step 3. Lift rod slowly, and guide carefully.

7 Moderate

16 Align box end of rod with pin end of drive sub and slowly bring together.

Lifting rod too much, causing it to kick out.

20 High

Never stand in direct line with rod, stand to one side. Use head traverse lever to take up the bit of slack not winch

4 Low

17 Slowly engage forward rotation to do up thread

Rod Crosses threads, causing hook to spin -Personal injury

23 High Rotate slowly. Hold hook in left hand with thumb in upright

position so it can pull free if rod kicks. Right hand on rod to steady Use head traverse not which if more tension required on rope. Gloves

8 Moderate

18 Raise head to release hook. Lower winch to removing hook and clamshell

Hook and cable pull too tight rod kicks out.

24 High

Check rod is done up before removing hook and clamshell. Drill Assistant to tighten by hand before removing hook (if unsure). Gloves

12 Moderate

19 Hook head rod up to rod line to recommence drilling.

WARNING

WARNING

239



Title: Differential Stick 1, 2 and 3 Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

Differential sticking occurs when rods become stuck due to differential pressure. To free, proceed as follows:

1 METHOD 1.

2 Mix drilling fluid of lower density. Personal injury — chemicals in eyes skin irritation

24 High

Wear protective goggles. Read and comply with relevant MSDS information

8 Moderate

3 Circulate low density drilling fluid,

4 Maintain pull on stuck rod string.

5 When rods are free, condition hole with drilling fluid and circulate hole.

Personal injury — chemicals in eyes skin irritation

17 Moderate

Wear protective glasses. Ensure easy access to MSDS sheets

7 Moderate

6 METHOD 2.

7 Disconnect drill rod on surface. Personal Injury sprains strains cuts and abrasions

20 High

Correct use of hand tools. SWP SURGEN 2.19 Stilson Use

7 Moderate

8 Bail or aerate drilling fluid, or pull inner tube fast to lower fluid head.

Personal Injury —— Struck by moving object, Entangled in wire line.

20 High

Keep clear of wireline. SWP SURDIA 5.07 Seat Tube Recovery

4 Moderate

9 Connect drill rod again and pull string. Personal Injury sprains strains cuts and abrasions

20 High

Correct use of hand tools. 7

Moderate

10 When free, rotate, condition hole with drilling fluid circulate.

Personal injury — chemicals in eyes skin irritation

24 High

Wear protective glasses. Ensure easy access to MSDS sheets

8 Moderate

11 Continue drilling.

METHOD 3.

Differentially stuck casing can be caused by casing not being seated properly and the cuttings/muds packing off on the back side of the borehole.

Correct diagnosis needs to be made between stuck casing due to swelling clays etc. Seat casing to stop water return coming up the annulus between the borehole and the casing.

240



Title: Differential Stick 1, 2 and 3 Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

12 Casing stuck at end of hole completion Casing parting 20

High

Pour a freeing agent down the backside of casing and leave hole until completion of next hole. Then come back over and casing should remove freely.

8 Low

241



Title: Stuck Rods Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Rods stuck in the hole.

Damage to and or loss of rods, down hole tools. Loss of hole. Re drill

18 Moderate

Try to avoid getting stuck in the first place. Signs of sticking may include; Sludge in the hole, rods sticking when pulling back, high torque, high water pressure. Clay bands and badly broken formations being present in the core. In horizontal directional drilling known faulted zones and tuft bands may be the problem area. Try to identify and act on the signs before the rods become stuck.

5 Low

2 When rods get stuck.

Notify your supervisor. Write down the following information; Exact depth of hole, if on bottom, if pulled back, how far off bottom, tube in or out, circulation yes, no, circulation pressure, possible cause of stuck rods. What was happening leading up to the rods becoming stuck.

3 Attempt to recover the tube. Every effort must be made to prevent the problem becoming worse.

Getting overshot stuck on tube, belling rods, pulling rods apart, Think each step through discuss with supervisor before proceeding.

18 Moderate

Check operation of dry release. Do not lower over shot in to the hole unless you are sure the over shot can be released from the tube should the lube be stuck in the barrel.

5 Low

4 Tube stuck in barrel 18

Moderate

Try to diagnose why the tube is stuck; i.e., core not broken core is mushroomed in the bit, split lifter case, burnt, latch spring broken, blown rubbers, belled tube etc.

5 Low

5 Record all information Measure and record all the dimensions of all equipment lowered

into hole. Keep client informed of progress.

6 Options; Seek advice from supervisor, area manager,

Recover tube and drill through the barrel, complete hole with smaller size rods. Stuck rods can be cut off and recovered at the completion of the hole. Cut off rods and wedge or navi drill around stuck rods. SWP DIR 812 Haul Rowe Wedge

242



Title: Stripping Impregnated Bits Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Bit can become polished due to the ground becoming too hard for the bit.

Slow penetration. Excessive weight needed to maintain penetration. Incorrect bit selection.

13 Moderate

Select correct bit for ground being drilled. Closely monitor bit weight and penetration rate. Check core for changes in ground.

5 Low

2

Increase weight on bit. Reduce rotation speed.

Reduce water flow. This procedure is not to be used for surface set bits.

DRY STRIPPING A SURFACE SET BIT WILL RENDER IT

USELESS.

Burning bit to bottom of hole. 18

Moderate

Watch for increase in torque as the bit sheds the worn diamonds. Be ready to lift the bit off bottom as soon as stripping occurs. Set torque limiter.

5 Low

3

Resume drilling at the settings that were used before the bit became polished. Adjust weight, rotation and pump speed as required.

Bit polishing again. Excessive bit wear.

12 Moderate

Closely monitor drilling to prevent the bit becoming polished again. If bit continues to polish, pull out and change to a softer matrix bit.

4 Bit will not strip. Penetration very slow or stopped. Excessive weight required.

18 Moderate

Pull inner tube. Pump down a hand full of broken up grindstone, glass or similar hard material of about dice size. Reseat inner tube lower bit to bottom and apply about half the drilling weight and slowly rotate with reduced water for a few revolutions. Do this twice ensuring torque limiter has been adjusted. Lift the bit off bottom and resume drill as before. lf bit continues to polish, pull out and change to a softer matrix bit.

8 Moderate

WARNING

243



Title: Stripping Impregnated Bits Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

5 DRY STRIPPING A BIT This practice is a last resort and should only be conducted under supervision.

6

Reduce excessive pull down and balance rods. Increase rotation 100rpm. Set torque limiter 10to 20 bar or one cant above drilling torque. Turn off fine control lever and turn on coarse control lever.

7 As torque starts to flicker up wards. Engage fine control lever and as the bit bites lift smoothly off bottom.

This procedure should only be conducted under supervision or with approval from the supervisor.

WARNING

244


Title: Assembly of Q Series Outer Tube Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Set up trestles in safe working area. Personal injury – lifting 17

Moderate Safe manual handling procedure Training against procedure SWP SURHSE 1.02 Manual Handling

2 Lay barrel on trestles Personal injury – lifting 17

Moderate

Safe manual handling procedure Training against procedure Gloves

7 Moderate

3 Check barrel for bends, dents, splits etc., inspect box and pin thread for damage.

Personal injury – lifting 17

Moderate Safe manual handling procedure Training against procedure

7 moderate

4 Clean and Grease threads.

5 Coat outside of landing ring with never seize.

6 Insert correct landing ring into box end of barrel and push down onto shoulder in barrel.

7 Use both sides of landing ring before discarding.

8 Screw reamer and adaptor coupling into box thread and hand tighten. Use stilsons to tighten up joint.

Personal injury – tool slips 12

Moderate

Follow Stilson use Have 3mm -5mm gap between hook jaw reamer, barrel, etc., Never tighten threads with stilsons on the box without pipe screwed into it. It will squash the thread.

5 Low

9

Don’t stand on stilsons to tighten.

10 If using 6 and 9 meter barrel ensure a stabilizer is positioned between each join in the box end.

WARNING

WARNING

245






RESIDUAL RISK SCORE

11 Fit correct brass inner tube stabiliser into front reamer shell. Anti-seize the stabilizer.

Note PQ stabiliser is fitted in the bit.

12

Screw reamer onto pin thread of outer barrel and hand tighten. Use stilsons to tighten up joint, making sure the stilsons on the reamer is placed between the diamonds on the reamer and the pin thread to avoid damaging diamonds.


Moderate

Follow Stilson use Training against procedure Never stand on stilsons SWP SURGEN 2.19 Stilson Use.

5 Low

13 Grease reamer pin thread.

14

Select suitable bit and screw onto reamer, tighten as per step 8, taking care to keep stilsons away from face of bit. Do not over tighten.


Moderate Follow Stilson use Training against procedure

5 Low

15 Store barrel in safe area. Personal injury – lifting 17

Moderate Safe manual handling procedure Training against procedure

7 Low

246






RESIDUAL RISK SCORE

247


Title: Assembly of Q Series Inner Tube Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Set up trestles in safe working area. Personal injury – lifting 20

High

Safe manual handling procedure. SWP SUR!-ISE 1.02 Manual handling. Train people to this work instruction

8 Moderate

2 Lay inner tube on trestles. Personal injury – lifting 20

High Safe manual handling procedure. Train people to this work instruction

8 Moderate

3 Check inner tube is straight and undamaged.

4 Check threads are clean and undamaged.

5 Check tube is empty and clean inside. Personal injury – eyes 21

High

Always look down inner tube. Never attempt to catch falling objects Wear appropriate PPE

2 Low

6 Check back end is in good condition i.e. Bearings, latches, pins, rubbers etc.

Damaged Equipment – injury

16 Moderate

If any damaged parts refer MAINT 8.017 Train people to this work instruction

7 Screw back end into inner tube and hand tighten.

8 Tighten with tube spanners but be careful not to over tighten.

Personal injury – hand tools Damage to equipment

16 Moderate

Correct use of hand tools. Use the right tool for the job

2 Low

9 Use grease gun to grease back end. Equipment damage 12

Moderate Check grease has penetrated bearings, (it will flow from relief holes

3 Low

10 If bearing doesn’t take grease, replace nipple and try again.

11 Check and oil knucklehead assembly.

12 Lubricate litter case Inspect case for cracks

13 Fit core lifter. Check condition of lifter

14 Fit stop ring.

15 Check stop ring has locked in position.

16 Check core lifter if still grabs core.

17 Screw lifter case onto inner tube and hand tighten.

248


Title: Assembly of Q Series Inner Tube Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

18 Tighten with tube spanners but do not over tighten. Personal injury – hand tools 16

Moderate Correct use of hand tools.

4 Low

19 Check tube length is correct, if not adjust as in.

20 Store in safe area with knucklehead turned down. Personal injury – lifting & cuts

24 Moderate

Safe manual handling procedure SWP SURHSE 1.02 Manual Handling Train people to this work instruction

8 Low

249


No: SURDIA5.22 Prepared By: Vaughan Cullen Title: Assembly of Q Series Inner Tube Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK

SCORE

CHAPTER 5

Maintenance – Between Core Runs

Head Assembly

1. Wash the head assembly in clear water to remove drilling mud and grit.

2. Inspect the action of the latching and the latch retracting case. Both should work freely. Check the spindle for straightness.

3. Check the movement of the spindle bearings. They should spin freely and there should be no vertical end play. If end play exists, the head assembly needs further repairs. (See Chapter 6: Inspection and Maintenance – After Service.)

4. Check the shut-off valve for shredding.

5. If no parts have been replaced and the bearings are in good condition, apply grease to the latches and the latch retraction case. Pump “Shell Alvania EP2” or equivalent grease into the grease fitting until clean grease flows out of the grease relief hole in the thrust hole. Rotate the inner tube trap slowly to distribute the grease while pumping.

6. Rejoin the head assembly to the inner tube, ready for the next core run (Figure 5A).

Inner Tube Assembly

1. Check the Core Lifter Case, Stop Ring and Core Filter (Figure 5B). The core lifter should rotate freely. If the inside surface of the core lifter is smooth, check the grip action of the core lifter. Insert a short section of the core into the core lifter and pull it out to see if the core lifter will fully grip the core. If the core slips, the core lifter or the core lifter case should be replaced.

2. Before you can extract a worn core lifter, you must remove the stop ring:

- Insert a screwdriver blade in the ring and pry loose.

- Rotate the stop ring so that the ring hoop is at 90 degrees with the diameter of the core lifter case and pull it out.

- Replace the worn core lifter.

To replace the stop ring:

- Slide it in the 90 degree position.

- Rotate the hoop 90 degrees and snap into the recess.

- Grease the outside of the core lifter.

Visually inspect the inside of the core lifter case to be sure the stop ring is properly positioned.

250


Title: Assembly of Q Series Inner Tube/Adjust Length Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan (Note: SWP SURDIA5.23 replaces SURDIA5.24)




RESIDUAL RISK SCORE

1 Set—up trestles in sate working area. Lifting, personal injury. 16

Moderate

Safe manual handling procedure SWP SURHSE 1.02 Manual Handling Train and Assess employees to this instruction.

2 Lay inner tube on trestles. Personal injury sprains and strains lifting

16 Moderate

Safe manual handling procedure Train and Assess employees to this instruction.

4 Low

3 Check inner tube is straight, clean and undamaged. Personal injury 21

High

Always look down inner tube. Never attempt to catch falling objects Wear appropriate PPE

4 Low

4 Wash I.D. of inner tube to remove fit.

5 Wash split tubes and lightly oil or apply a detergent to the O.D. of the splits.

6 Brace inner tube against a stop and push in lower split leave approximately 30cm protruding.

Hand injury, split hard to push, out hand.

16 Moderate

Wear protective gloves. 4

Low

7 With care start top split and push in level with bottom split.

Gloves to be worn

8 Push both splits into the inner tube. Hand injury. 16

Moderate Wear protective gloves.

4 Low

9 If splits will not push in by hand, stand inner tube with splits facing down and dump on clean wood surface until splits are flush with inner tube end.

Foot injury. Splits may be dumped on foot. Splits cross over

7 Moderate

Wear protective footwear. Visually inspect splits aren’t crossed May need to pump out splits

4 Low

10 Apply thread grease to inner tube thread and fit cleaned and assembled core case, core lifter and stop ring.

Spot ring fitted up side down Core lifter not gripping.

Stop ring angle side must face split tubes, and must look in position. Lubricate inside of core case. Check core lifter is gripping using a piece of core.

11 Tighten core case with tube wrenches, do not over tighten.

Personal injury — hand tools.

11 Moderate

Correct use of hand tools. li tube kicks up whilst tighten assemble backend first or ask for assistance. Gloves to be worn

4 Low

12 Remove piston plug from pump out

251


Title: Assembly of Q Series Inner Tube/Adjust Length Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan

(Note: SWP SURDIA5.23 replaces SURDIA5.24)




RESIDUAL RISK SCORE

piston, clean piston and check "O" ring for damage.

13

Fit pump out piston into other end of inner tube. Tap carefully with rubber mallet if necessary and make sure "O" ring does not get damaged on sharp end of thread of inner tube.

"O" ring gets caught on thread end of inner tube – damaged "O" ring.

4 Moderate

Squeeze "O" ring while pushing piston into position. 2

Low

14 Apply thread grease to inner tube thread, clean back end and check it is in good condition.

15 Screw back end to inner tube by hand, tighten with tube wrenches.

Personal injury — hand tools.

11 Moderate

Correct use of hand tools. 4

Low

16 Use grease gun to grease backend,

17 Check grease has penetrated bearings; it will flow from relief holes.

If any damaged parts refer MAINT 8.017 Train and assess people to this work instruction

18 lf bearing does not take grease, replace grease nipple and try again,

19 Check and oil knuckle head assembly. Check latches are operable.

20 Check tube length is correct. If not, adjust as per Longyear manual, Refer to diagram in SWP SURDIA5.25

21 Make sure knuckle head is turned down. Personal injury 8

Moderate The knuckle head downwards

4 Low

252


Title: Assembly of Universal Water Swivel Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Place main swivel body in vice. Do not over tighten and crush body out of shape

Personal injury – lifting 16

Moderate

Refer to Manufacturers parts book Follow safe manual handling procedure SURHSE 1.02 Manual Handling.

4 Low

2 Hand pack thrust bearing with grease

3 Place bottom bearing race in housing and gently tap down with hammer and punch until flush on bottom of housing.

Personal injury 16

Moderate

Correct use of hand tools Tap the inside of race not outside. PPE: eye protection, gloves

4 Low

4 Follow same procedure with bearing and top race

5 Fit main spindle into housing, with spanner flats at bottom and make sure it sits flush on bearing

6 Close vice jaws until about 75mm gap

7 Sit housing on laws and close jaws firmly on spindle

8 Pack ball bearing with grease

9 Put bearing over spindle and tap down until it sits flush on spindle flange

Personal injury 11

Moderate Correct use of hand tools PPE: eye protection

4 Low

10 Fit retaining circlip and make sure it locks into housing recess

Personal injury 11

Moderate Correct use of hand tools PPE: eye protection

4 Low

11 Place spacer on spindle followed by locking washer

12 Screw spindle nut onto spindle and tighten. Do not overload bearings

13 Align a tab on locking washer with recess on spindle nut and gently bend up with a flat head screwdriver

Personal injury 11

Moderate Correct use of hand tools

4 Low

14 Grease thread on spindle extension and screw into spindle. Note: This is a left hand thread

253






RESIDUAL RISK SCORE

15 Place screwdriver across recesses in spindle extension and tighten.

Personal Injury 11

Moderate Correct use of hand tools PPE

16 Fill housing to about 5mm below lip with grease

17 Fit brass packing housing over spindle and push down until it seats neat on housing

18 Smear a film of grease on the inside of the packing housing and outside of the spindle extension to allow vee packing to slide easily into place

19 Place vee packing over spindle extension (vee's upwards) and push down. It may be necessary to separate packers to fit grease in between packers.

20 Sit compression spring over extension spindle and on top of vee packing

21 Sit "o" ring in brass packing housing

22 Grease threads and screw hoisting cap on Note: This is a left hand thread

23 Housing should spin freely on spindle when cap is done up

24 Place main spindle body back in vice

25 Place bar through cap bail arm and tighten or use stilsons

Personal Injury 11

Moderate

Ensure stilson is clean jaws are sharp right size for the job and visually inspect the spring is in good condition. Wear gloves. Have 3mm - 5mm between hook jaw & drill rod

4 Low

26 Pump grease into swivel

254

STANDARD WORK PROCEDURE No: SURDIA5.25 Prepared By: Vaughan Cullen Coordinator





RESIDUAL RISK SCORE

255






RESIDUAL RISK SCORE

15 Place screwdriver across recesses in spindle extension and tighten.

Personal Injury 11

Moderate Correct use of hand tools PPE

16 Fill housing to about 5mm below lip with grease

17 Fit brass packing housing over spindle and push down until it seats neat on housing

18 Smear a film of grease on the inside of the packing housing and outside of the spindle extension to allow vee packing to slide easily into place

19 Place vee packing over spindle extension (vee's upwards) and push down. It may be necessary to separate packers to fit grease in between packers.

20 Sit compression spring over extension spindle and on top of vee packing

21 Sit "o" ring in brass packing housing

22 Grease threads and screw hoisting cap on Note: This is a left hand thread

23 Housing should spin freely on spindle when cap is done up

24 Place main spindle body back in vice

25 Place bar through cap bail arm and tighten or use stilsons

Personal Injury 11

Moderate

Ensure stilson is clean jaws are sharp right size for the job and visually inspect the spring is in good condition. Wear gloves. Have 3mm - 5mm between hook jaw & drill rod

4 Low

26 Pump grease into swivel

256



Title: Mounting & Dismounting Work Platform Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 When mounting work platform first ensure walkway is clear.

Personal Injury. Slip, Trip, Fall 20

High Ensure safe working area All walkways have safety rails

7 Moderate

2 Hands should be free to hang on to stairway handles.


High Three points of contact when mounting or dismounting the work platform.

7 Moderate

3 Mounting and dismounting should always be carried out by facing the work platform.


High Ensure correct footing.

7 Moderate

4 Always maintain three points of contact when mounting and dismounting.

One foot two hands One hand two feet

257


Title: Changing Q Series Backend Parts Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Set up trestles in safe working area. Personal injury — lifting. 17

Moderate Safe manual handling procedure

2 Lay inner tube on trestles. Personal injury — lifting. 17


7 Moderate

3

While back end is still connected to inner tube, use tube spanners to crack thread between spindle bearing and inner tube cap assembly. Do not "snap" tube wrenches to undo tight threads.

Personal injury — hand tools 17

Moderate

Correct use of hand tools. Rest one wrench on solid surface and use both hands to apply pressure to second wrench. Make sure you are well balanced. Ensure level surface

5 Low

4 Use tube spanners to crack thread between inner tube cap assembly and inner tube, and then unscrew back end from tube.


Moderate

Correct use of hand tools Refer to Manufactures parts book for additional information

5 Low

5 Place back end on clean flat working surface in a safe area.

Personal injury — lifting. 17


7 Low

6 Unscrew inner tube cap assembly.

7 Wipe excess grease oft compression spring with rag. Equipment damage 10

Moderate Ensure rag is clean and free of impurities

3 Low

8 Use shifting spanner to unscrew and remove self-locking nut.



5 Low

9 Slide compression spring off spindle.

10 Slide hanger bearing off spindle.

11 Slide spindle bearing off spindle.

12 Slide thrust bearing off spindle.

13 Slide shutoff rubbers and adjusting washers off spindle.

14 Clean parts and inspect for wear and damage.

15 Replace parts as necessary.

258






RESIDUAL RISK SCORE

16 Reassemble following steps 13 — 8.

17 Adjust self-locking nut until bearing forces slight pressure on shut off valves.



5 Low

18 Screw cap assembly back on and tighten with tube spammers - Do not over tighten.



5 Low

19 Use grease gun to grease back end.

20 Check grease has penetrated bearings (it flows from relief holes). If not, check bearing is in a correct way.

21 If bearing doesn't take grease, replace nipple and try again.

22 Back end is ready to reassemble on inner tube. Personal injury — hand tools 12


5 Low

23 Store in safe area with knucklehead turned down. Personal injury — lifting, cuts 17


7 Low

24 Refer to diagrams below for additional information.

259






RESIDUAL RISK SCORE

260






RESIDUAL RISK SCORE

261


No: SURDIA5.28 Prepared By: Vaughan Cullen Title: Changing Q Series Backend Parts Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK

SCORE

Inner Tube Assembly

1. Using Boar Longyear tube wrenches remove the inner tube cap from the spindle bearing (Figure 6A) and wash out the grease within the cap.

2. Clean the grease from me compression spring and from the bearings and the spindle shaft.

3. Check both the thrust and hangar bearings to see that the cages are not broken and that the races are spinning freely. If replacement is required, it is very Important to ensure that the bearings are installed correctly (Figure 6B). If you look at the top and bottom of one of the bearings you will notice that one of the inside diameters is larger than the other. The difference in diameters is very important during installation of the bearings. The larger inside diameter must always face the spindle bearing to allow proper grease flow. After installation, pump grease into the inner tube cap assembly until grease squirts out of grease relief hole in the thrust bearing.

NOTE: Thrust type hall bearings have two different inner diameters. For correct installation, the largest inner diameter must contact the spindle. Wrong bearing installation can reduce the head life and cause excessive core lifter wear.

4. It the rubber shut-off valves or any of the bearings need replacing (Figure 6C), than remove the self- locking nut arm and strip the spindle shaft of all parts, keeping the bearings together as a group. Inspect ball check spring and stainless steel ball for caked dirt or water.

7. Reassemble the inner tube cap to spindle bearing (Figure 6A). Pump grease into inner tube cap until it is full and grease squirts out of the grease relief hole in the thrust bearing (Figure 6B). Check the lower edge of the landing shoulder ring for wear. If it shows signs or wear it can be reversed by unscrewing the upper latch body from the lower. The ring is a slip fit on the lower latch body.

8. Check the action of the latching mechanism. It should operate smoothly and freely. Apply cup grease to the latches and the latch retraction case.

9. lf the latches or links show excessive wear, remove worn latches by removing latch retraction case and driving out the spring pin (See Assembly and Disassembly instructions on page 17).

10. When installing new latches, the latches must fit within the case relative lo the slots in the latch retraction case.

11. Pump “Shell Alvania EP2” or equivalent grease until it flows up through the thrust bearings.

12. Check the spearhead assembly for wear. Replace as necessary.

13. Attach the inner lube to the head assembly.

14. Set the inner tube assembly aside and service the outer tube assembly.

Inspection and Maintenance – After Service

5. Check me spindle assembly shaft for wear and shaft straightness. Although some shaft wear is permissible, replace the shaft if gaps or grooves are visible.

6. Thread soil-locking nut to spindle. Tighten the self-locking nut so the compression spring is not pre-loaded. There should he no up and down bearing end play, however, all the bearings must spin freely.

262


Title: Core Orientation with Pencil Tip Spear (W/Line) Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 At completion of drilling run, flush hole to remove cuttings

2 Measure stick up with tape measure

3 Lift bit off bottom, feeling for core break giving some idea if core is sitting up in hole.

4 Break rod joint and lower overshot to retrieve inner tube


High

Correct use of hand tools — Stilsons SWP SURGEN 2.19 Stilson Use SWP SURDIA 5.07 Seat Tube Recovery

4 Low

5 When overshot latches onto back end, pull back to torque indicates tube is connected and mark wireline

6 Pull back wireline 6m and place warning mark

7 Retrieve inner tube Personal injury sprains and strains manual handling

16 moderate

SWP SURDIA 5.07 Seat Tube Recovery Follow correct procedure Train on these written work instruction. Gloves

4 Low

8 Inspect core break, it core break not too steep, continue with orientation

9 Break overshot and connect orientation spear making sure that pencil only protrudes approximately 2cm and is sharpened to expose lead

Personal injury - hand tools - steel splinters

16 Moderate

Correct use of hand tools — Stilsons SWP SURGEN 2.19 Stilson Use Train on these written work instruction. Wear appropriate PPE — gloves

7 Low

10 Lower orientation spear to warning mark on wireline and wait for wireline to stead .

11 Lower orientation spear slowly so as to mark core with pencil

263


Title: Core Orientation with Pencil Tip Spear (W/Line) Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

12 Retrieve orientation spear slowly through the barrel and inspect pencil break

13 Lift bit off bottom and seat inner tube

14

At completion of next run, retrieve core, locate centre of mark. Mark with an orientation pencil. Along the core in a straight line from the centre of ORl mark.

Follow instructions from client on additional marking. ORl to be written on core block.

264


JSA SWP ■

No: MAINGEN 6.00 Prepared By: Vaughan Cullen Equipment Type: Hydraulic Hose Title: Change and Repair Hydraulic Hoses Approved By: Vaughan Cullen Vehicles & Plant: Nil Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Isolate and tag equipment. Personal injury. Live equipment

23 Tag out equipment. 2

2 Using correct size spanner, unscrew hose from fittings

Personal injury Hand abrasion strain.

20 Wear all appropriate PPE Ensure hand tools are fit for purpose Wear safety glasses

4

3 Seal both fittings with plugs

4 Hose - Swaged fittings. Replace with identical hose.

Equipment Damage Personal injury, crush fittings, hit by flailing object.

24

Ensure that fittings and hose are as per manufacturer’s specifications. Do not use non compatible fittings or hose No correct fittings or hose available STOP work activity

2

5 Hose - Reusable fittings.

6 Clamp ferrule in vice.

7 Unscrew insert. Personal injury — hand tools. 17 Correct use of hand tools. 2

8 Clamp hose in vice and unscrew ferrule by turning clockwise.

Personal injury — hand tools. 16 Correct use of hand tools. 2

9 Cut hose to right length, ensuring it is cut squarely Personal injury — hand tools. 24 Use tools correctly. Wear gloves.

4

10 Clean hose bore. Personal injury 23 Do not direct compressed air towards the body. 4

11 Lubricate outer cover

12 Clamp hose in vice and screw ferrule on anti-clockwise.

Personal injury — hand tools. 16 Correct use of hand tools. 2

13 Screw insert into ferrule. Do not allow hose to turn during operation.

14 Remove plugs and fit hose. Personal injury — hand tools. 16 Correct use of hand tools. 2

15 Remove warning tags.

16 Start up and check for leaks.

265


JSA SWP ■

No: MAINGEN 6.01 Prepared By: Vaughan Cullen Equipment Type: Hydraulic Pressure Gauge Title: Change Hydraulic Pressure Gauge Approved By: Vaughan Cullen Vehicles & Plant: Nil Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Isolate all energy and tag equipment. Personal injury 23 Tag out equipment. 4

2 Ensure ell pressure is released then clean around fitting and hose.

Ensure that all hydraulic pressure is released before attempting to loosen hydraulic fitting

3 With correct size spanners undo hydraulic hose or pipe.

Personal injury 7 Correct use of hand tools. Wear all appropriate PPE- especially protective safety glasses

4

4 Undo nuts for holding bracket and remove bracket. Personal injury 7 Correct use of hand tools. 4

5 Pull out gauge through control panel.

6 Undo fittings from gauge. Personal injury 7 Correct use of hand tools. 4

7 Apply thread sealant on new gauge and screw on fittings.

Personal injury 7 Correct use of hand tools. 4

8 Fit gauge in control panel.

9 Fit holding bracket and tighten the two nuts. Personal injury 7 Correct use of hand tools. 4

10 Fit hose or pipe to fitting and tighten. Personal injury 7 Correct use of hand tools. 4

11 Remove tag as per tag out procedures.

12 Start up and check for hydraulic leaks.

266


JSA SWP ■

No: MAINGEN 6.02 Prepared By: Vaughan Cullen Equipment Type: Bean Pumps Title: Change Balls and Seats – Bean Pumps Approved By: Vaughan Cullen Vehicles & Plant: Nil Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Isolate and tag equipment. Personal injury – moving pump parts

20 Tag out equipment. Wear all appropriate PPE—especially protective safety glasses

2

2 Remove all plugs in discharge or suction inlets. Personal injury – skinned knuckles

16 Correct use of hand tools. 4

3 Remove the six nuts on the studs. Personal injury – skinned knuckles

16 Correct use of hand tools. 4

4 Slide the three cover clamps off the studs. Personal injury – cut hands 16 Correct use of hand tools. 4

5 Slide the three valve covers from the valve chamber.

6 Rotate the shaft so one plunger is on the complete down stroke.

7 Place the valve seat remover tool or a blunt rod against the suction valve seat and using a hammer, drive the suction valve seats loose.

Personal injury – squashed fingers

12 Correct use of hand tools. Wear protective gloves and safety glasses

4

8 Remove the valve through valve cover opening.

9 Remove all three suction valves in the same manner.


10 Insert the blunt tool through the opening for the suction valves and position against the discharge valve seat.

11 Using the hammer, drive the discharge valve out the chamber discharge opening.

Personal injury 12 Correct use of hand tools. Wear protective gloves and safety glasses

4

12 Repeat until all discharge valves are removed. Personal injury 12 Correct use of hand tools. 4

13 Check that all surfaces on the valve are free from ticks, burrs and dirt and are dry. Replace any necessary parts.

267


JSA SWP ■

No: MAINGEN 6.02 Prepared By: Vaughan Cullen Equipment Type: Bean Pumps Title: Change Balls and Seats – Bean Pumps Approved By: Vaughan Cullen Vehicles & Plant: Nil Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

14 Insert suction valves squarely in the suction valve openings through the valve cover openings.

15 Place a dowel approximately the diameter of the valve and drive the valve firmly in the valve chamber.

Personal injury 12 Correct use of hand tools. Wear protective gloves and safety glasses

4

16 Insert discharge valves through the discharge opening so the ball is toward the outside of inlet openings.

17 Have the discharge valves firmly in place as in step Personal injury 12 Correct use of hand tools. Wear protective gloves and safety glasses

4

18 Inspect the "o" rings or gaskets on the valve cover, have damaged replace. Carefully replace valve covers taking care not to damage "o" rings

19 Replace valve cover clamps.

20 Replace six nuts and tighten

268


JSA SWP ■

No: MAINGEN 6.03 Prepared By: Vaughan Cullen Equipment Type: Bean Pumps Title: Replacing Plunger Packing – Bean Pumps Approved By: Vaughan Cullen Vehicles & Plant: Nil Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Isolate and tag equipment. Personal injury – moving pump parts

22 Tag out equipment. 4

2 Check the corner nuts on the valve chamber to assure that they are tight.

Personal injury 7 Correct use of hand tools Wear appropriate PPE

4

3 Remove the six hexagonal nuts on the front of the valve chamber.

Personal injury 7 Correct use of hand tools. — Socket set Wear appropriate PPE

4

4 Slide the three cylinder cover clamps from the valve chamber.

5 Remove the three cylinder covers. It may be necessary to tap on the sides of the covers to free them from the chamber.

Personal injury 7 Correct use of hand tools — Hammer Wear appropriate PPE

4

6 Inspect "o" rings or gaskets on the cylinder covers. If damaged, replace with new "o" rings.

7 Insert a socket wrench into the valve chamber onto the hexagonal nut in the valve packing. Turn the wrench to the left and remove the nut

Personal injury 7 Correct use of hand tools — Spanner Wear appropriate PPE,

4

8 Insert the packing removal tool. While rotating the tool to the right pull the packing assembly from the cylinder and out through the valve chamber.

Personal injury 7 Correct use of hand tools — Packet Removal Tool Wear appropriate PPE,

4

9 Place the packing holder in a vice. Now rotate the nut counter clock-wise using the FMC packing tool.

Personal injury 7 Correct use of hand tools — Packet Removal Tool Wear appropriate PPE,

4

10

Remove the old packing from the packing holder and replace with new packing, Then re-insert packing washer and packing nut into packing holder and retighten packing nut

Personal injury 7 Correct use of hand tools — Screwdriver Wear appropriate PPE,

4

11

Pump should be rotated slowly to bring the rod to the front of the cylinder before installing the packing. This will reduce the distance the packing must be driven into the cylinder and minimise the chance of damage or misalignment.

269


JSA SWP ■

No: MAINGEN 6.03 Prepared By: Vaughan Cullen Equipment Type: Bean Pumps Title: Replacing Plunger Packing – Bean Pumps Approved By Vaughan Cullen Vehicles & Plant: Nil Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

12 Inspect the "o" ring on the end of the plunger rod and replace if necessary.

13

Packing assembly can now be installed with one or two sharp raps against the tool with a 24 oz. or heavier hammer. It installation is not accomplished by two or three blows, lubrication is necessary.

Personal injury 11

Correct use of hand tools- Packing tool and hammer. Wear appropriate PPE

4

14 Replace the nut in the packing nut with a socket hand wrench and turn clockwise.

Personal injury 7 Correct use of hand tools — Socket set. Wear appropriate PPE

4

15 Replace the cylinder covers and cylinder cover clamps.

16 Replace cover clamp nuts and tighten. Personal injury 7 Correct use of hand tools — Spanners. Wear appropriate PPE

4

270


JSA SWP ■

No: MAINGEN 6.04 Prepared By: Vaughan Cullen Equipment Type: Relief Valve Title: Overhaul Relief Valve Approved By: Vaughan Cullen Vehicles & Plant: Nil Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Isolate and tag equipment if applicable Personal injury 21 Tag out equipment using company tag out procedures 4

2 Undo brass locknut Personal injury 8 Correct use of hand tools. Wear protective safety glasses

4

3 Undo brass adjusting screw Personal injury 8

Relieve pressure from spring Correct use of hand tools. Make sure adjusting screw is fully unwound to relieve pressure from spring

4

4 Unscrew safety valve from pipe fitting Personal injury 7 Correct use of hand tools. 2

5 Put safety valve in vice

6 Unscrew zinc plated steel plug and remove Personal injury 7 Correct use of hand tools. 2

7 Remove thrust washer, spring guide, spring and pull valve

8 Tap out valve seat by tapping on seat from bottom valve body


9 Clean and inspect all parts and replace if necessary.

10 Place new valve seat and ball valve in body and tap down on ball to seat valve seat in body


11 Place compression spring, thrust washer and spring Inside.

12 locknut to adjusting screw

13 adjusting screw to steel plug

14 steel plug to valve body and tighten Personal injury 7 Correct use of hand tools. 2

15 relief valve to pipe fitting and tighten Personal injury 7 Correct use of hand tools. 2

16 Start pump and adjust relief valve to correct pressure

17 Tighten locknut Personal injury 7 Correct use of hand tools. 2

18 move tag as per tag out procedure Personal injury 7 Follow tag out procedures 2

271


JSA SWP ■

No: MAINGEN 6.05 Prepared By: Vaughan Cullen Equipment Type: Cable Clamps Title: Fitting Cable Clamps Approved By: Vaughan Cullen Vehicles & Plant: Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Select correct cable clamps for cable Personal injury — clamp 20 Check clamps match cable size Wear appropriate PPE

4

2 Double over cable and fit eyelet

3 Fit bridge (saddle) on working (long) side of cable and U-bolt on dead end (short) side of cable. Never saddle a dead horse

Reduced rope efficiency Personal injury — cable failure

24 Ensure clamps are fitted correctly. Wear appropriate PPE

4

4 For cables up to 18mm (¾") tit at least 3 clamps. For cables 18 mm—3O mm (¾%" - 1¼%") fit at least 4 clamps

Incorrect fitted cable clamps greatly reduce load ratings always check condition of cable

5 Clamps should be spaced approximately 6 rope diameters apart

6 Tighten clamp nuts Personal injury — hand tools 11 Follow correct use of hand tools — Spanner. Wear appropriate PPE

2

7 Do not severely tighten grip farthest from eyelet

8 Recheck clamps after one or two lifts

272


JSA SWP ■

No: MAINGEN 6.06 Prepared By: Vaughan Cullen Equipment Type: Nil Title: Replace Alternator on Diesel Engine Approved By: Vaughan Cullen Vehicles & Plant: Diesel Engines Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Ensure sate working area Personal injury 12 Ensure safe working area. On mobile equipment apply handbrake and chock wheels before commencing.

4

2 Tag out equipment Personal injury 20 Follow company tag out procedures 2

3 Disconnect battery Personal injury 22 Disconnect negative lead first Wear appropriate PPE

4

4 Mark all electrical cables going into alternator

5 Remove all electrical cables Personal injury 7 Correct use of hand tools 2

6 Loosen nuts on alternator bracket and pivot Personal injury 7 Correct use of hand tools 4

7 Push alternator towards engine

8 Slide belts off pulley

9 Remove bolts and nuts from alternator Personal injury. Damage to equipment

7 Ensure alternator is adequately supported 4

10 Lift out alternator Personal injury 11 Correct safe manual handling procedures 4

11 Fit new alternator with bolts and nuts Personal injury 11 Correct safe manual handling procedures 4

12 Pull alternator away from engine to tighten belts

13 Tighten bolts on bracket and pivot Personal injury 11 Correct use of hand tools 4

14 Connect all electrical cables.

273


JSA SWP ■

No: MAINGEN 6.07 Prepared By: Vaughan Cullen Equipment Type: Diesel Engines Title: Replace Starter Motor on Diesel Engine Approved By: Vaughan Cullen Vehicles & Plant: Nil Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Ensure safe working area Personal injury 12 Ensure safe working area On mobile equipment apply handbrake and chock wheels before commencing

4

2 Tag out equipment Personal injury working on live equipment

20 Following tag out isolation procedures. 4

3 Disconnect battery Personal injury 22 Disconnect negative lead first Wear appropriate PPE

3

4 Mark all electrical cables going into starter motor

5 Loosen nuts and remove all electrical cables Personal injury 7 Correct use of hand tools Wear appropriate PPE

2

6 Loosen all nuts holding starter motor Personal injury 7 Correct use of hand tools Wear appropriate PPE

4

7 Remove nuts and lift out starter motor Personal injury 11 Manual lifting Train and assess on these written work instruction. Wear appropriate PPE

4

8 Fit new starter motor and tighten all nuts Personal injury 11 Correct use of hand tools Manual lifting Train and assess on these written work instruction.

4

9 Connect all electrical cables Personal injury 11 Correct use of hand tools Wear appropriate PPE

4

10 Connect battery Personal injury 11 Connect negative lead last 4

274


JSA SWP ■

No: MAINGEN 6.08 Prepared By: Vaughan Cullen Equipment Type: Title: Replace V-Belts on Diesel Engines Approved By: Vaughan Cullen Vehicles & Plant: Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Ensure sate working area and engine is cool Personal injury – Burns 12

Ensure safe working area Wear appropriate PPE On mobile equipment apply handbrake and chock wheels before commencing

4

2 Tag out equipment

3 Disconnect battery Personal injury 22 Disconnect negative lead first 4

4 Loosen nuts on alternator bracket and alternator pivot. lf fitted with idler pulley undo locknut and wind down bolt to loosen belts

Personal injury 11 Correct use of hand tools 2

5 Push alternator towards engine to loosen belts

6 Slide belts off pulleys

7 Relace with new belts

8 Pull alternator to tighten belts or tighten bolt on idler pulley


9 Tighten nuts on alternator bracket or locknut on idler pulley


10 Check tension on belts by putting pressure on belts between pulleys. Movement down should be about 10mm

275


JSA SWP ■

No: MAINGEN 6.09 Prepared By: Vaughan Cullen Equipment Type: Diesel Engine Title: Replace Water Hoses on Diesel Engines Approved By: Vaughan Cullen Vehicles & Plant: Nil Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Ensure sate working area and engine is cool Personal injury – Burns 12

Ensure sate working area Wear protective gloves and protective safety glasses On mobile equipment apply handbrake and chock wheels before commencing

4

2 Tag out equipment

3 Disconnect battery Personal injury 22 Disconnect negative lead first 4

4 Release pressure in radiator Personal injury burn 18 Release pressure in radiator. Ensure radiator has cooled down sufficiently. Wear appropriate PPE - safety glasses

4

5 Undo hose clamps Personal injury 11 Correct use of hand tools Beware of hot coolant

2

6 Pull off old hose Personal injury – scrape knuckles

11 Wear appropriate PPE – gloves 4

7 Smear grease inside new hose and fit to engine

8 Tighten hose clamp Personal injury 11 Correct use of hand tools 2

9 Fill up with coolant

10 Connect battery Personal injury 22 Connect negative lead last 4

11 Start engine and check for leaks.

276


JSA SWP ■

No: MAINGEN 6.10 Prepared By: Vaughan Cullen Equipment Type: Battery Title: Charge 12 Volt Battery Approved By: Vaughan Cullen Vehicles & Plant: Nil Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Undo and remove negative connection first Personal injury — battery shorts out - Fire

23

Wear appropriate PPE-Protective safety glasses and gloves Remove negative first Correct use of hand tools Ensure fire extinguisher is available

8

2 Undo and remove positive connection Personal injury — battery shorts out - Fire

23

Remove negative first Correct use of hand tools Ensure fire extinguisher is available Battery fumes are explosive never expose to a naked flame, sparks etc.

8

3 Clean top of battery of dirt and dust Personal injury – acid burns 23 Wash area thoroughly if any skin contact Wear appropriate PPE ——safety glasses — gloves

4

4 Remove all plugs Personal injury – acid burns 23 Wear appropriate PPE —safety glasses and gloves Wash area of skin thoroughly if an contact

4

5 Check acid level in battery should be 1cm over plates

Personal injury – acid burns 23 Wash area of skin thoroughly if any contact 4

6 Connect leads from battery charger to battery positive to positive, negative to negative

Personal injury — battery explosion

23 Check leads are connected properly before switching charger on

4

7 Switch on battery charger Personal injury — battery explosion

23 Check leads are connected properly before switching charger on

4

8 When battery is fully charged, switch off charger and remove leads

11 Allow battery to cool before being put back in service Service life will be reduced if battery is not cooled

4

9 If level is low fill with distilled water Acid overflow 18 Only top up battery fluid after charging is completed 2

10 Screw all plugs back on battery Personal injury – acid burns 4 Wash area thoroughly if any skin contact 2

11 Fit positive connection to battery Personal injury — battery shorts out

16 Fit positive connection first 4

12 Fit negative connection to battery Personal injury — battery shorts out

16 Fit positive connection first 4

277


JSA SWP ■

No: MAINGEN 6.11 Prepared By: Vaughan Cullen Equipment Type: Diesel Engine Title: Jump Start 12 Volt Battery Approved By: Vaughan Cullen Vehicles & Plant: Nil Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Connect positive + (RED) clamp of jump set to positive terminal of boost battery. Connect other end to positive terminal of rig battery

Personal injury — battery shorts out – Fire

25

Ensure leads are connected correctly Ensure tire extinguisher is available Wear protective safety glasses and gloves Make sure that all switches are turned off and ensure connections are tight.

8

2 Connect negative - (BLACK) clamp of jump set to negative terminal of boost battery. Connect other end to negative terminal of rig battery


25 Ensure leads are connected correctly Ensure fire extinguisher is available

8

3 TO DISCONNECT

4 Remove negative lead of jump set from negative terminal of rig battery. Remove other end from negative terminal of boost battery


25

Ensure leads are disconnected correctly Ensure fire extinguisher is available Do not allow jumper lead clamps to touch together or touch the rig.

8

5 Remove positive lead of jump set from positive terminal of rig battery. Remove other end from positive terminal of boost battery


25 Ensure leads are disconnected correctly Ensure fire extinguisher is available

8

278


12 VOLT SYSTEM

279


JSA SWP ■

No: MAINGEN 6.12 Prepared By: Vaughan Cullen Equipment Type: Battery Title: Jump Start 24 Volt System Approved By: Vaughan Cullen Vehicles & Plant: Nil Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 When connecting boost batteries connect one boost and one rig battery at a time

Make sure that all switches are turned off and ensure connections are tight,

2

Connect positive + (RED) clamp on number one jump set to positive terminal of number one boost battery Connect other end to positive terminal of number one rig battery.


25

Ensure leads are connected correctly Wear appropriate PPE- Protective safety glasses and gloves Ensure fire extinguisher is available

8

3

Connect negative — (BLACK) clamp on number one jump set to negative terminal of number one boost battery. Connect other end to negative terminal of number one rig battery.


25

Ensure leads are connected correctly Ensure fire extinguisher is available Wear appropriate PPE- Protective safety glasses and gloves

8

4

Connect positive clamp of number two jump set to positive terminal of number two boost battery. Connect other end to positive terminal of number two rig battery


25

Ensure leads are connected correctly Ensure fire extinguisher is available Wear appropriate PPE- Protective safety glasses and gloves

8

5

Connect negative clamp of number two jump set to negative terminal of number two boost battery. Connect other end to negative terminal of number two rig battery.


25 Ensure leads are connected correctly Ensure fire extinguisher is available Wear appropriate PPE- safety glasses and gloves

8

TO DISCONNECT

6

Remove negative clamp of number two jump set from negative terminal of number two rig battery, remove other end from negative terminal of number two boost battery


25

Ensure leads are removed correctly Ensure fire extinguisher is available Wear appropriate PPE- safety glasses and gloves Do not allow jumper lead clamps to touch together or touch the rig

8

7

Remove positive clamp of number two jump set from positive terminal of number two rig battery, remove other end from positive terminal of number two jump battery.


25

Ensure leads are removed correctly Ensure fire extinguisher is available Wear appropriate PPE- Protective safety glasses and gloves

8

280


JSA SWP ■





RESIDUAL RISK SCORE

281


JSA SWP ■





RESIDUAL RISK SCORE

8

Remove negative lead of number one jump set from negative terminal of number one rig battery. Remove other end from negative terminal of number one boost battery


25 Ensure leads are removed correctly Ensure fire extinguisher is available

8

9

Remove positive lead of number one jump set from positive terminal of number one rig battery. Remove other end from positive terminal of number one boost battery


25

Ensure leads are removed correctly Ensure fire extinguisher is available Wear appropriate PPE- Protective safety glasses and gloves

8

282


JSA SWP ■

No: MAINGEN 6.13 Prepared By: Vaughan Cullen Equipment Type: Rig Title: Vibrating Noise from Head - Transmission Approved By: Vaughan Cullen Vehicles & Plant: Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Flush hole clean of cuttings

2 Pull at least 6m of rod string Personal injury 23

Correct use of hand tools Wear appropriate PPE- gloves and safety glasses

4

3 Rest remaining rod string in foot clamp lf rig is offline it can cause down hole vibration

4 Break rod joint Personal injury 20

Correct use of hand tools Wear appropriate PPE— gloves and safety glasses

4

5 Lift head above rods resting in clamp

6 Rotate head and find out where noise comes from Rotating Spindle Personal injury

24 Keep distance from rotating spindle 2

7 Consult supervisor

283


JSA SWP ■

No: MAINGEN 6.14 Prepared By: Vaughan Cullen Equipment Type: Title: Light Vehicle Daily Inspection Approved By: Vaughan Cullen Vehicles & Plant: Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1

Check ■ oil level ■ radiator water level ■ brake fluid ■ clutch fluid ■ condition of belts and hoses

Burns, engine failure Brake failure Clutch failure Damage through overheating engine

23

Do not remove radiator cap while engine is hot, or if competent release pressure before removing cap and top up. Top brake and clutch fluids to correct levels Replace belts & hoses as per service procedure

8

2

Visually inspect ■ All lights are working ■ Rotating beacon is working ■ Jack and wheel brace in vehicle ■ Spare Tire ■ Fire extinguisher

No visibility in dark or warning lights Reduces vehicle visibility

17 Replace globes, check wiring & fuses 4

3

After start up ■ Listen for unusual noises ■ Check brake pedal for excessive travel ■ Check rear view mirrors are adjusted

Potential damage to vehicle Personal Injury -Brake failure if distance from pedal to floor is less than 75mm

21 Stop vehicle, isolate & report Stop vehicle, isolate & report

7

4

After Use ■ Fuel vehicle for next shift ■ Clean rubbish out ■ Fix or replace flat Tires ■ Close up windows & lock vehicle if

necessary

Fire hazard 21 Re-fuel as per SWP Ensure correct fire extinguisher is available * Train and assess employees on this work instruction.

7

284


JSA SWP ■

No: MAINGEN 6.15 Prepared By: Vaughan Cullen Equipment Type: Truck Title: Truck Daily Check Approved By: Vaughan Cullen Vehicles & Plant: Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1

Check ■ oil level ■ radiator water level ■ brake fluid ■ clutch fluid ■ condition of belts and hoses ■ drain air tanks ■ tires are inflated

Burns, engine failure Brake failure Clutch failure Damage through overheating engine Compressed air – eye injury

23

Do not remove radiator cap while engine is hot, or if competent release pressure before removing cap and top up. Top brake and clutch fluids to correct levels Replace belts & hoses as per Major service procedure Wear safety glasses

8

2

Visually inspect ■ All lights are working ■ Rotating beacon is working ■ Jack and wheel brace in vehicle ■ Spare Tire ■ Fire extinguisher ■ Wheel nuts

No visibility in dark or warning lights Reduces vehicle visibility

17 Replace globes, check wiring & fuses 4

3

After start up ■ Listen for unusual noises ■ Check brake pedal for excessive travel ■ Check rear view mirrors are adjusted ■ Check dash lights and gauges are working

Potential damage to vehicle Personal Injury -Brake failure if distance from pedal to floor is less than 75mm

21 Stop vehicle, isolate & report Stop vehicle, isolate & report

7

4

After Use ■ Fuel vehicle for next shift ■ Clean rubbish out ■ Fix or replace flat Tires ■ Close up windows & lock vehicle if

necessary

Fire hazard Personal injury

21

Re-fuel as per SWP Ensure correct fire extinguisher is available * Train and assess employees on this work instruction. Refer VEH 4.4 Remove flat tires - trucks

7

285


JSA SWP ■

No: MAINGEN 6.16 Prepared By: Vaughan Cullen Equipment Type: Light Vehicle Title: Remove Flat Tyre – Light Vehicle Approved By: Vaughan Cullen Vehicles & Plant: Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Park on flat surface, put vehicle in neutral, apply hand brake and turn off ignition.

Personal injury – vehicle moves

17 Apply hand brake, chock wheels 7

2 Chock wheels to prevent vehicle rolling

3 Get tools and equipment required for job Personal injury – manual handling

16 Follow safe manual handling procedure 4

4 Loosen wheel nuts on flat tire Personal injury – hand tools 16 Correct use of hand tools 4

5 Place jack under correct lifting point

6 Jack up vehicle Personal injury – jack slips 16 Make sure jack is placed on level ground. Never get under jacked up vehicle

4

7 Undo wheel nuts, remove flat tire Personal injury – hand tools manual lifting

21 Correct use of hand tools Follow correct safe manual handling procedure

7

8 Put new wheel on, fit nuts and do up firmly Personal injury – manual lifting

18 Follow correct safe manual handling procedure 4

9 Lower vehicle onto ground and remove jack Personal injury – jack slips 22 Never get under jacked up vehicle 7

10 Tighten wheel nuts securely Personal injury – hand tools 16 Correct use of hand tools 4

11 Replace all tools, equipment and flat tire Personal injury – manual handling

20 Follow correct safe manual handling procedure 4

12 Remove wheel chocks

13 Recheck wheel nuts after 20km Personal injury – hand tools 21 Correct use of hand tools 7

286


JSA SWP ■

No: MAINGEN 6.17 Prepared By: Vaughan Cullen Equipment Type: Trucks Title: Remove Flat Tyre – Trucks Approved By: Vaughan Cullen Vehicles & Plant: Revision Date: 5th Jan.2011 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Park on flat surface, put vehicle in neutral, apply hand brake and tum off ignition

Personal injury – vehicle moves

17 Apply hand brake, chock wheels 7

2 Chock wheels to prevent vehicle rolling

3 Get tools and equipment required for job Personal injury – manual handling


4 Loosen wheel nuts on flat tire Personal injury – hand tools 16 Correct use of hand tools 4

5 Place jack under correct lifting point

6 Jack up vehicle Personal injury – jack slips 20 Make sure lack is placed on level ground. Never get under jacked up vehicle

8

7

Undo wheel nuts, on spider rims, tap lugs with hammer to release tension before removing nuts. Remove flat tire. lf removing inside dual tire, spacer must be removed first

Personal injury – hand tools manual lifting Wheel lugs flying off

18

Correct use of hand tools Tap lugs with hammer to release tension before removing nuts. NB It is very important to release tension on the lug while nut is still on the wheel-stud. Follow correct safe manual handling procedure GEN 1.11

7

8

Put new wheel on, replace spacer if necessary. lf using spider rims centralise lugs before tightening wheel nuts. Place a tool on the ground as a reference point and spin wheel to ensure wheels are centralised

Personal injury – hand tools manual handling

18 Follow correct sate manual handling procedure GEN 1.11 Correct use of hand tools

4

9 Lower vehicle onto ground and remove jack Personal injury – jack slips 22 Never get under jacked up vehicle 7

10 Tighten wheel nuts securely Personal injury – hand tools 16 Correct use of hand tools 4

11 Replace all tools, equipment and flat tire Personal injury – manual handling


12 Remove wheel chooks

13 Recheck wheel nuts after 20km Personal injury – hand tools 21 Correct use of hand tools 7

287


JSA SWP ■

No: MAINGEN 6.18 Prepared By: Vaughan Cullen Equipment Type: Snowmobile Title: Snowmobile – Pre-Operational Check Approved By: Vaughan Cullen Vehicles & Plant: Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Ensure the throttle moves freely without sticking and returns to the closed or idle position once released

Throttle may stick or jam: Personal injury, equipment / property damage, loss of control

21 Clean throttle of dirt or debris prior to starting snowmobile and lubricate frequently.

2

2 Check brake control to ensure brakes apply when lever is operated and returns to normal position once released

Brakes may fail or jam: Personal injury, equipment / property damage, possible collision

21

1. Remove all ice, mud or dirt from brakes. 2. Inspect discs for wear. 3. If brakes are “soft", adjust brake cable periodically to allow for approximately ¾” play

2

3 Body work and hood Flying, flailing or loose parts; Personal injury, equipment / property damage, danger to others.

18 Inspect entire vehicle for loose parts or obvious defects and ensure hood is securely fastened.

4

4 Gas and oil levels Low gas or oil levels; Breakdowns, stoppages or seized engine.

24 Check fluid levels are adequate and ensure no leakages.

7

5 Steering

Personal injury / Equipment / property damage: Handlebars do not move freely, excessive play in steering linkage or ski connections.

17 Remove accumulated snow, ice or dirt from under hood and check steering linkages for excessive play; adjust as necessary.

2

6 Drive belt and Guard Personal injury: immobilized machine, belt could be worn or guard out of alignment or loose.

11 Replace belt if excessively worn and ensure guard is secure by tightening wing nuts.

2

7 Track

Personal injury: Track sticks, cracked or clogged with foreign objects. Snowmobile must be inert when checking track.

21 1. Remove key from ignition 2. Remove debris, ice, dirt 3. Check for cracks /damage

2

8 Headlights, high and low beams, taillights and brake light

Personal injury, property / equipment damage, collision, danger to others

22 1. Clean light lenses 2. Test high, low beams and brake light 3. Check taillights are working correctly

5

9 Emergency kill switch Personal injury, property / equipment damage, collision, danger to others

22

1. Test emergency kill switch to ensure it will stop the engine. 2. If a Tether Switch is attached to clothing verify that it works by pulling on the tether.

5

10 Checklist Personal injury, property / equipment damage, collision, danger to others

21 Checklist must be completed before operating machine

4

288


JSA SWP ■

No: MAINGEN 6.18 Prepared By: Vaughan Cullen Equipment Type: Snowmobile Title: Snowmobile – Pre-Operational Check Approved By: Vaughan Cullen Vehicles & Plant: Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan

SNOWMOBILE CHECKLIST Yes / No

Operator can demonstrate ability to safely handle snowmobile

Mandatory Signs for PPE, gloves, goggles, helmets, etc.

Means for emergency contact (Phone, radio, etc.)

List of emergency contact numbers

Cowlings Fitted and in good condition

Fuel Filter in good condition and fuel lines free of crack or leaks

Fittings tight and not leaking

Drive belt free of wear and cracks

Width of drive belt must compare with manufacturer’s specifications Spare drive belt

Tracks in good condition, no broken cleats, loose or torn drive holes or ply separation

Skis properly aligned, no loose weld joints, loose or worn wear rods or excess wear on bottom

Chain lubricated and tensioned correctly tension as per manufacturers recommendation

Shocks and free of fluid leaks

Lights and indicators working correctly, including brake light

Brakes proper adjustment and free operation (Set brake and test against acceleration)

Windshield fitted, clean and free of cracks or other damage

Snow flap fitted to rear of unit

Pulley and belt guard fitted and working correctly

Running boards and passenger grips fitted and in good condition

Fire extinguisher fitted, complete with Monthly Inspection tag and endorsed

Basic emergency toolkit (Spark plug wrench, spare drive belt, allen keys, wrenches, shovel, etc.)

First aid kit available, complete with Content and Monthly Inspection Record

Emergency kit

289


JSA SWP ■

No: MAINGEN 6.19 Prepared By: Vaughan Cullen Equipment Type: Skidder Title: Pre-Operational Check – Skidder Approved By: Vaughan Cullen Vehicles & Plant: Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

Only Trained and Competent Operators are Authorised to Operate Skidder.

Undera no Circumstance are Unauthorised Operators Allowed to Operate Equipment

1 Complete "pre-operational" inspection before starting the engine

Personal injury: Slip and fall 5

Wear appropriate PPE- protective safety glasses, gloves, coverall, hard hat, hearing protection and steel cap boots/shoes, Examine area for obstacles and slippery surface, i.e. ice, water, oil

1

2 Check oil coolant, hydraulic fluid reservoir and fuel tank for level and leakages

Contact with hazardous materials or fumes.

12 Ensure gloves are worn, contact with hazardous material—wash off immediately with clean water for at least 15 mins.

2

3 Inspect drive belts for condition and tension, clamps for tightness and effectiveness and filters for condition, including possible leaks

Contact with hazardous materials, pinch points

7 Wear appropriate PPE- protective safety glasses, gloves, coverall, hard hat, hearing protection and steel cap boots/shoes.

2

4 Check tires, and wheels for visible damage, pressure and loose nuts

Contact with sharp products in tire, foreign bodies, wrench slipping off wheel nut

7 Wear appropriate PPE- protective safety glasses, gloves, coverall, hard hat, hearing protection and steel cap boots/shoes,

2

5 Electrical wires for fraying, insulation and connections

Electrical short, loss of power, fire, electrical shock

13 Report to Supervisor or lf serious fault Lock out—Tag out LOTTO Skidder until repaired

8

6 Check fire extinguisher for availability and condition.

Discharged, out-of—service, poor condition, inappropriate for application

18

Inspect: 1. Pressure gauge; Green segment shows fully

charged Red segment indicates low pressure. 2. Provide B-C type extinguishers for skidder fire

protection. 3. Check locking pin is available and seal is

intact. 4. Check hose for cracks and excessive wear. 5. Inspect barrel for leaks or fractures and

general condition. 6. Inspect extinguishers monthly and endorse

inspection record or punch aluminium card.

3

Never Operate Unsafe Equipment – Tag Out Equipment – Report all Problems to Supervisor Immediately

290


JSA SWP ■





RESIDUAL RISK SCORE

7 Bolts and connections Equipment failure, personal injury, poor efficiency

21 Ensure appropriate bolts and connections are tight and secure

8

8 Guards and shields Personal injury, equipment damage, expose personnel to moving or rotating equipment

21 Ensure guards and shields are in place, inspect for cracks or damage and are effective

8

9 Winch rollers, cable, clamps, shackles, hooks

Cable presents greatest threat as it could snap and dangerously whip in any direction. Personal injury, equipment damage, danger to others, property damage.

19

Inspect; l. Winch rollers turn easily and are greased 2. Cable for damage, kinks, loose or broken

strands, flattened spots or excessive wear 3. Hook for general condition and ensure gap is

not excessive 4. Shackles for condition and bolts are tight 5. Ensure clamps are installed correctly and a

minimum of four are installed.

8

10 Chain Adjustment on the tires (if applicable) Unit could lose traction, Personal injury , equipment/property damage,

13 Inspect the tire chains for broken links and adjust tension if necessary

4

11 Cracks to the frame and blade Personal injury, equipment/property damage

18

Inspect frame and blade for cracks or excessive wear. It is important to regularly wash the frame and blade down to prevent material build – up that could easily hide cracks and excessive wear.

2

12 Handholds, steps, door handles and hinges

Threat of falling is greater during colder months when extra care must be exercised when ascending steps or using handholds due to ice and/or material build up. Personal injury, slip and fall,

12 Ensure handholds, steps, door handles and hinges are cleaned of ice or other material and inspected regularly.

4

13 Condition of operator’s seat and safety belt Fatality, Personal injury 25

lf a Roll Over Protection System (ROPS) is provided the operator must wear a seat belt at all times while in the cabin to restraint the operator in the case of a roll - over incident and the seat must be in good condition

7


291


JSA SWP ■





RESIDUAL RISK SCORE

14 Check cleanliness of engine and power train

Dirty engine and power train could disguise serious mechanical problems. Personal injury, equipment damage

18 Clean engine and power train regularly to prevent a build—up of material

8

15

Inspect gauges and lenses Unable to accurately gauge speed or status of operating systems. Personal injury, equipment damage, danger to others

25 Damaged gauges must be repaired otherwise the unit should be Locked Out – Tagged Out until repaired

2

16 Inspect grease nipples Loss of efficiency, equipment may

seize, personal injury, equipment damage

13 Grease nipples must be routinely checked and grease applied as necessary

4

17 Check radiator Loss of fluid may cause unsafe

condition, personal injury or/and equipment/property damage

21 Fluid level to be checked daily and topped up or changed as required

4

18

Inspect windows and wipers Loss of clear view, personal injury, danger to others, equipment/property damage

20

Windows must be kept dirt free and wipers must work efficiently, cracked windows must be replaced/ repaired and worn wipers must be replaced as soon as possible.

4


292

STANDARD WORK PROCEDURE No: DIR 8.01 Prepared By: Vaughan Cullen Title: Navi Drill Pre-Check Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Test the navi tool on surface by turning the rotating bit sub box with 18" stilsons in a clockwise direction

Personal Injury Hand tools 2

Low

Compliance with SWP SURGEN 2.19

Stilson use

1 Low

2

If lower shaft rotates freely, fit filter in front of orientation sub, attach to navi tool and pump clean fresh water into the tool. The lower shaft and bit will start turning at approximately 50 PSI water pressure


Stilson use

3

Disconnect and pour 2-3 L vegetable based oil into rotor and stator for lubrication while rotating bit and bit box manually with stilson in a clockwise direction

Personal Injury Hand tools 2

Low


Stilson use

SWP SRHSE 1.02 Manual handling

1 Low

4 Turn and locate the highside of the tool. Tool not in correct position while setting the mule shoe. Untrue orientation

16 Moderate

Supervisor must supervise setting of mule shoe 4

Moderate

5

Undo the locking nut of the mule shoe and place mule shoe into the orientation sub at the back of the navi tool allowing the mule shoe to locate the orientation pin inside the sub

6 Adjust the brass compass insert to vertical so it is in line with the bend on the navi tool

7 Tighten lock nut making sure the compass insert has not moved

8 Take a survey shot

9

Scroll through to find GRoll function on REFLEX camera St reading should be 0/360 Degrees then the bend in Navi Tool is facing the same way

10 If the GRoll is not 0/360 Degrees undo locknut on muleshoe and turn and re—survey until GRoll does read 0/360 Degrees

293


No: DIR 8.01 Prepared By: Vaughan Cullen Title: Navi Drill Pre-Check Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

11

For an Eastman camera continue as from step 7. The tool orientation mark (three black lines) on the survey disc and the lumber line should line up indicating tool is set at 0/350 degrees (highside).

12 Make sure the lead on the mule shoe is not marked already and is extended enough for the orientation pin to strike and leave a mark

Pin not striking the lead properly. No mark on lead, incorrect orientation

21 High

“Stretch" lead by tapping lead on mule shoe with hammer and punch gloves and eye protection

7 Moderate

13 The navi tool is now ready to lower down hole. Make sure project leader inspects survey before lowering tool

14 Once tool is ran into required depth it needs to be orientated to the required direction off highside (0/360 degrees)

294


No: DIR 8.02 Prepared By: Vaughan Cullen Title: Down-Hole Motor Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1

Down Hole Motor Drilling is designed to alter hole direction and in most cases is a decision that is made by the site geologist so that they get to drill through their designated target zone.

2

Prepare for down hole motor drilling Once the decision has been made to Down Hole Motor Drill the hole should be flushed clean and surveyed, then the rods pulled out of the hole.

Personal Injury Strains

17 Significant

Use correct manual handling procedure SWP SURHSE 1.02 Manual Handling Wear correct PPE Ensure instigating 2 man lifts

5 Low

3

Make up and measure down hole motor. The Down Hole Motor is to be measured to get a total length (this will be different to the barrel length so you will have a different stick up when you get to bottom).

Refer SWP SURDlA5.18 SWP SURGEN 2.26 Calculate Hole depth SWP DIR 8.01 Navi Check Orientation

4 Lower down hole motor in to the hole

SWP DIR 8.01 Navi Check Orientation SWR SURDIA 5.11 Pull and Run Rods Hoist plug Test run the down Hole Motor on surface before running down hole. Orientate the Down Hole Motor so that the direction of the Down Hole Motor bend coincides with the orientation mark on the camera compass. Always run smaller diameter rods behind Down Hole Motor to reduce water pressure, The absolute minimum amount of rods is to be at least the length of the Down Hole Motor cycle.

295


No: DIR 8.02 Prepared By: Vaughan Cullen Title: Down-Hole Motor Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

5

Prepare for down hole motor drill run. Lower Down Hole Motor down hole, flushing periodically until you reach the last rod before touching bottom. Connect rods onto rotation head and run Down Hole Motor for approx. five minutes to ensure that there is no grease or substances in rod string to prevent Down Hole Motor from running or being orientated.

6

Orientate down hole motor. Disconnect head and Orientate Down Hole Motor to the direction that the hole must go (in most cases you need to allow for rod torque and ground pull). After each orientation shot, the rods will need to be turned to the desired direction, engage micro feed up (to take out stretch) and turn rods with stilsons to required direction. Each time they are turned run the rods up and down approx. 3 metres to make sure they have turned at the bottom of the rod string. Re survey after each time tool is turned

Personal injury Crush

18 Significant

Make sure that rod string is unable to move anti clockwise (back rods up with stilsons). Lock off rotation levers. Place head in low gear. Use Auscut, bit lube or a similar lubricant when drilling with motor. Refer SWP DIR 8.01 Navi Check Orientation SWP SURGEN Stilson Use 2.19 Gloves For negative torque; As a guide allow 5 degrees for every 100 metres of BQ As a guide allow 1 degrees for every 100 metres of NQ

5 Low

296


No: DIR 8.02 Prepared By: Vaughan Cullen Title: Down Hole Motor Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

7

Drilling with down hole motor. Connect rotation head up to rods and run water at a high rate to get Down Hole Motor spinning, Run rods slowly to bottom (the weight and water pressure will tell you when you touch bottom). Then slowly increase bit weight until Down Hole Motor stalls, then decrease weight slightly, this will generally give you the best penetration rate.

Check specification of Motor The Down Hole Motor may stall from time to time due to broken or hard ground, lf this happens lift rods slightly off bottom then slowly put rods back on bottom and continue drilling. Slow penetration rate if this continues.

Aim for 150 to 200 differential pressure whilst drilling. Make sure that rod string is unable to move anti clockwise (back rods up with stilsons). Lock off rotation levers. Place head in low gear. Use Auscut, bit lube or a similar lubricant when drilling with motor.

8

End of down hole motor run. Pull rods out of hole and remove Down Hole Motor. Conduct open hole survey to confirm completion of motor run.

Personal injury Strains

17 Significant

SWP SURDIA 5.11 Pull and Run Rods Hoist plug Correct manual handling procedure SWP SURHSE 1.02 Manual Handling Wear correct PPE 2 man lifting where necessary SWP SURGEN Stilson Use 2.19

5 Low

9 Clean all subs and tools run rock drill oil through DHM and seal both ends of tool store in clean storage area in a clean state ready for next use.

Personal injury Handle Chemicals

17 Significant

Apply SWP SURHSE1.14 Chemical Handling Refer to MSDS Correct manual handling procedure SWP SURHSE 1.02 Manual Handling Wear correct PPE 2 man lifting where necessary SWP SURGEN Stilson Use 2.19

3 Low

10 lf any doubts or confusion with any steps, check with supervisor prior to starting job

297

STANDARD WORK PROCEDURE No: DIR 8.03 Prepared By: Vaughan Cullen Title: Down Hole Motor Navi Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Consultation between Geologist, Driller and Supervisor Incorrect Information 10

Moderate

Ensure all information is clear and understood by all concerned

3 Low

2 Survey bottom of hole Incorrect information 10

Moderate Check survey, if unsure discuss with supervisor. 3

Low

3 Flush Hole, ensure hole is clean and clear of cuttings and obstacles

Stop flushing to soon 10

Moderate

Check water return where possible, turn rods making sure hole is free and stable.

3 Low

4 Pull Rods, count rods and double check hole depth Observe SWP for this task

SWP SURDlA5.11

17 Significant Make sure hole depth is correct

3 Low

5 Measure lengths of DHM and all subs — record all measurements and retain records

Incorrect R/S Length 17

Significant Go through this procedure with driller’s assistant 6 Low

6 Set DHM to required curvature and lock Possible incorrect curvature 17

Significant Double check 2

Low

7 Set DHM to top dead centre and set survey angle unit to same. Lock mule shoe

Possible Incorrect orientation 17

Significant Double check 2

Low

8 Run DHM on surface noting all water pressures run tor approximately 10 minutes

Moving Equipment 18

Significant Keep all personal well clear while testing 3

Low

9 Suspend OHM in hole and clamp with independent clamp

Drop DHM in hole 17

Significant

Have all correct equipment on site prior to be in operation.

6 Low

10 Connect rods to DHM and run into hole. Run smaller rods behind down hole motor IE, NQ size hole BQ rods minimum length of DHM

Drop DHM in hole. High water pressure restriction in bend required

17 Significant All rods to be ready to run in. All rods ready.

4 Low

11 Run rods to within 3mtrs of bottom Drop Rods 17

Significant

Apply SWP for rod tripping.

SWP SURDIA 5.11

5 Low

12 Run OHM to check operation note water pressure. DHM Failure 17

Significant Run approximately 5 minutes. 3

Low

13 Run survey camera into orientation sub and take survey.

Mule shoe not seated incorrect reading Camera not fitted properly

17 Significant

Check mule shoe seated by painting leading edge of mule shoe or with lead pin.

5 Low

14 Recover camera and check reading Dangerous Chemical combined 17

Significant Wear appropriate PPE 3

Low

15 Orientate DHM to required direction and Loosen Rods 17 Always turn rods in Drilling Direction even if 3

298





RESIDUAL RISK SCORE

re survey using same methods as before. Note in deep holes allow for rod twist.

Significant required to turn almost 350 degrees Low

16 Once orientation complete mark rods at 12 o clock Loss of Mark 14

Significant Clean rod prior to marking. 5

Low

17 Run Rods close to bottom and hook up ready to bore. Marking rods at 12 o clock as you go.

Rods turning incorrect direction of DHM.

15 Significant Ensure rod markings stay at 12 o clock

5 Low

18 With down hole motor bit spinning run rods slowly to bottom. Drill, check motor orientation every six metres using camera survey equipment

Negative Rotation 15

Significant

Back up rods against mast with stilson wrench and secure to that position.

5 Low

19 Complete cycle and recover DHM Drop rod string hang up in hole 18

Significant

Stay alert to all hang ups in hole. Have all tools, clamps ready for use

5 Low

20

Run in rod string with appropriate barrel and reamers, barrel and reamer configuration may vary depending on degree of bend in hole, ream out entire cycle distance. Note: amount of rotation torque and drill to suite application

Drop Rods, stuck in hole, broken rods

20 Significant

Work to SWP’S for running rods, don't over penetrate through cycle bend

6 Low

21 Drill off bottom of cycle, 3 to 9 metres past and survey Tight in hole 5

Low If necessary ream through cycle again. 5

Low

22 Clean all subs and tools run rock drill oil through DHM and seal both ends of tool store in clean storage area in a clean state ready for next use.

Personal injury

Handle Chemicals

17 Significant

Apply SWP SURHSE144

Refer to MSD s sheets

3 Low

23 If any doubts or confusion with any steps check with supervisor prior to starting job.

299





RESIDUAL RISK SCORE

24 Make sure hole has been cleaned thoroughly from sludge and down hole additives - mud — bit lube etc.

Sludge or additives in hole. Navi drill gets sludged in. Repeat whole procedure

16 Moderate

Hole must be washed with fresh clean water before pulling rods to run navi tool

4 Low

25 Wash navi tool within 3m of bottom so that rod join is above clamp

26 Check condition of survey camera and run survey camera with mule shoe making sure the lead is ok and unmarked

Photo taken while still lowering survey camera. Incorrect orientation Leaking “o” rings Worn thread Flat batteries Camera not loaded

11 Moderate

Check condition of “o” rings Check condition of camera barrel and threads. Check all threads are tight. Seal “o” rings with Vaseline Check battery life Check film in camera if using a single shot camera. Allow extra time when setting the time. Camera travels slow inside BQ rods

2 Low

27

Run camera to bottom making sure you slow down when approaching the marker on the wireline. You should feel when the lead in the mule shoe hits the orientation pin

28 After the required timer pull survey camera and check that the lead in the mule shoe has been marked by the orientation pin

No mark on lead. Mule shoe has not landed properly Survey incorrect

16 Moderate

Repeat survey Warm up camera fluid Pull survey camera slowly at first to ensure it’s not stuck in muleshoe. Maximum speed of100 bar at idle on main pump pressure.

4 Low

29 If lead has been marked by the orientation pin, check survey disc

30

lf the navi tool has to be re-positioned connect rod string and but a mark on the rod string showing where the previous survey said the navi tool is pointing as you will read on the survey disc.

360 degree protractor will make it easier to mark correct direction of motor.

300


No: DIR 8.04 Prepared By: Vaughan Cullen Title: Run Survey Camera and Orientation Tool Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1

After each orientation shot, the rods will need to be turned to the desired direction, engage micro feed up (to take out stretch) and turn rods with stilsons to required direction, Each time they are turned run the rods up and down approx. 3 metres to make sure they have turned at the bottom of the rod string. Re survey after each time tool is turned

Personal Injury 20

High

Correct handling of hand tools Refer SWP DIR 8.01 Navi Check Orientation SWP SURGEN Stilson Use 2.19 Gloves For negative torque: As a guide allow 5 degrees for every 100 metres of BQ As a guide allow 1 degrees for every 100 metres of NQ

4 Low

2

Put rod string in clamp and break joint. Proceed as from step 3. This procedure may take a few times until the highside of the navi tool is pointing in the required direction.

3

Once the tool is in the required position as the lubber line on the survey indicates, hold the rod string in place by using 2 stilsons Lock off rotation levers Place head in low gear. Use Auscut, bit lube or a similar lubricant when drilling with motor.

Refer SWP DIR 8.01 Navi Check Orientation SWP SURDIR 8.02 Down Hole Motor for further information on drilling. SWP SURGEN Stilson Use 2.19 SWP SURGEN 2.17 Mix Mud Glove

301


No: DIR 8.05 Prepared By: Vaughan Cullen Title: Steel Tool Survey Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1

After drilling to a designated survey depth, the rods should be lifted oft the bottom and secured in the foot clamps. The rotation head should then be disconnected from the rod string, and traversed to the top of the mast.

2 Recover inner tube.

3

Fit survey pulley to head. Run survey cable. The rotation head should be traversed to the base of the mast. The pulley for running the survey cable is then fitted to the rotation head. When the pulley has been securely fitted and is facing the right way, the survey cable is then run over the pulley and the latch is closed. When enough slack cable has been run out the rotation head is again traversed to the top of the mast.

Personal injury. Lifting. Hand Tools

8 Low

SWP SURGEN 2.19 Stilson Use

SWP SURHSE 1.02 Manual Handling

Gloves

3 Low

4

Placing survey tool in hole. While one of the on site personnel holds and guides the pressure barrel containing the survey equipment (magnetometer and data probe), the survey technician, or a nominated person, will engage the winch and take the weight of the pressure barrel. While the person holding the pressure barrel guides it into the rod string, the person operating the winch should commence lowering the pressure barrel.

Personal injury. Lifting 8

Low


Gloves

3 Low

302






RESIDUAL RISK SCORE

3

Take survey cluster. The first survey cluster shot is taken at this point. When instructed by the surveyor one of the personnel on site will rotate the rod string 45 degrees clockwise. On occasions the use of stilsons may be required The computer will show on the screen when the rods have turned 45 degrees The next cluster shot may now be taken. These steps are repeated until a total of 8 cluster shots have been taken. (The computer will resolve the 8 cluster shots to 1 survey point.)

Personal injury. Manual handling. Use of stilsons

8 Low

SWP SURGEN 2.19 Stilson Use


Gloves

3 Low

4

Remove survey tool from drill string. The survey equipment may now be removed from the hole. When the survey equipment reaches the top of the rods, the entry process is reversed. The on site personnel will lay the survey equipment on the ground as the winch operator lowers the tool The rotation head is traversed down to the base of the mast, the pulley is removed from the head. The Rotation head is traversed up to the top of the mast, the core tube inserted, a drill rod added.

Equipment damage 13

Moderate

SWF SURGEN 2.19 Stilson Use


Gloves

8 Low

303






RESIDUAL RISK SCORE

5

Lower survey tool. Most winches are fitted with a meter to enable the operator to read the depth of the survey equipment. This allows the operator to check the depth of the hole and to ensure the survey tool is not landed too hard.

i.e. SLOW DOWN BEFORE LANDING.

Equipment damage 18

High 10

Moderate

6

Suspend drill string. When the Steer tool assembly has landed (cable goes slack), the operator checks the meter to confirm that the survey equipment has reached the survey depth, When this has been done a hoisting plug (cable removed) with a groove cut in it to accommodate the survey cable should be screwed into the rod string, The winch rope can now be refitted to the hoisting plug

Personal injury. Manual handling. Incorrect survey depth

13 Moderate SWP SURDIA 5.11 Pull/Run Rods with Hoist Plug

6 Low

WARNING

304


No: DIR 8.09 Prepared By: Vaughan Cullen Title: Pilot Hole Breakthrough Drilling Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Set up drill rig Incorrect drill set up 17

High

SWP SURGEN 2.05 Set UP/Move Surface Rig SWP SURGEN 2.06 Set Up Rig SWP SURGEN 2.22 Set Up Lighting Plant Site layout Plan Check accuracy of rig Inclination/Azimuth.

5 Low

2 Drill collar and place casing Conduct surveys as site instruction.

22

High

SWP SURAIR 3.01 RC Collar SWP SURMUD 4.01 Rotary Mud Collar Rig Inductions and crew training on task in place Signage and barricading as necessary Survey. Zero tolerance. Report results to Project Leader if survey results are unacceptable. Redrill if tolerance unacceptable.

7 Low

3 Commence drilling 22

High

SWP SURGEN 5.05 Diamond Drilling SWP SURGEN 2.26 Calculate Hole Depth SWP SURGEN 2.17 Mix Mud SWP COAGEN 13.05 Night Drilling Pre—start inspections Safety guarding and signage in place Conduct down hole survey as site instructions. Report results. Maintain hole straightness by controlled drilling.

7 Low

4 Continue to drill -40m above breakthrough Failure to stop within 40m of hole breakthrough.

25 High

Ensure adequate surveys to reduce risk of premature breakthrough and hole deviation.

12 Moderate

305


No: DIR 8.09 Prepared By: Vaughan Cullen Title: Pilot Hole Breakthrough Drilling Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

5

Stop drilling. Notify underground shift boss of intention to drill last 40m. Shift blasting. Driller to have shift blasting times before commencing drilling last 40m. Advise shift boss there will be large flow of drilling fluids released from drill hole break through.

Failure to stop within 40m of hole break through.

Risk of intersecting active mining heading.

Stuck drill pipe due to mine blast.

25 High

Shift boss ensures that no loaded blast holes and no electrical, air water services, machinery or personnel are within breakthrough area. Area to be barricaded with signs. Shift boss to advise Driller that area is secure before drilling commences. Shift boss to advise removal of above services only if required. Appropriate dewatering pumps in place.

8 Moderate

6

Ensure all safety control's are in place. a) Clear persons and equipment from area b) Inspect Backs for positions of g Cables and Services c) Hang appropriate hazard and warning signs Advise client there will be large flow of drilling fluids released from drill hole break through

Injury to personnel. 25

High

All personnel not to stand directly under drill head or on rig deck, when drilling last 40m breakthrough.

Pumps or sumps in place to control drilling fluids Hazard and Warning signs Training on task

12 Moderate

7 Flush hole clean and then commence drilling last40m of hole and Breakthrough.

Injury to personnel, Equipment damage

24 High

ADITC Competencies Reconfirm with shift boss that drilling is to commence, confirm that no personnel are within 50m radius of breakthrough area, all barriers and signage are in place. Correct drilling procedures, fluid pump engaged, rod string balanced.

8 Moderate

8 Flush hole clean of cuttings six meters before breakthrough

WARNING

306


No: DIR 8.09 Prepared By: Safety Train & Develop Coordinator Title: Pilot Hole Breakthrough Drilling Approved By: Training Assessor Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

5

Approaching break through. STOP

Serious injury

Unexpected break through

24 High

Then at 3m from breakthrough or as specified in the hole plan. All drilling operations shall cease until a AMWD and client representative have visually inspected the breakthrough area to ensure appropriate barricades and signage are in place. Once barricades and signage are in place. Pit ram / mine control shall be notified. Barricades shall stay in place until all phases of the hole opening process have been completed. SWP SURDIA 5.11 Pull/Run Rods Hoist Plug lf diamond drilling, the barrels used for directional drilling should be removed and replaced by a standard 3-metre work barrel. The work barrel should have the front and/or back reamers removed and replaced by blank reamers/standard adaptor coupling. The inner tube must also have a core lifter case fitted that has "V” cut in the leading edge. The rod string can now be run back into the hole to drill the last 3 meters to breakthrough.

8 Moderate

6 Breakthrough Causes of Hazard (notes) Complete water return loss before breakthrough

22 High

ADlTC Competencies When driller is confident that the hole has broken through he shall notify a Major supervisor the client geologist and the underground shift boss to confirm breakthrough. Water or air loss will be evident

12 Moderate

7 Removal of Drill String Injury to personnel 21

High

SWP SURDIA 5.11 Pull/Run Rods Hoist Plug SWP SURGEN 2.13 Main Winch Operation Pull out drill string from open hole

7 Moderate

8 Breakthrough completion Injury to personnel 24

High

Confirm with Shift boss all signs and barricades are in place to ensure no unauthorised access. Hole collar to be capped.

12 Moderate

WARNING

307


No: DIR 8.10 Prepared By: Vaughan Cullen Title: Pilot Hole Reaming Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Add next rod Personal injury. Rotating equipment

16 High

All personal shall stay well clear of any rotating equipment. Once hole is clean, close compressor airline and water valves and hold drill rod with spanner on top rod spanner flats, at slips table. PPE; Safety mask, glasses, hearing protection wear gloves. Ensure signage is in place SWP SURDIA 5.17 Pull/Run Rods with Clamshell SWP SURAIR 3.03 KL Rod Handler SWR SURAlR 3.05 Pull/Run RC Rods Conduct Pre—start inspections Correct use of hand tools. Check all parts of the rod handling assembly. Replace as necessary. Ensure the clamshell is the correct size for the rods that are in use Ensue lifting gear is tagged and in service, replace as necessary. Communication and training in the task. Never stand under suspended load

7 Moderate

2 Drilling on.

Open compressors airline and water line and commence drilling. SWP SURAIR 3.02 Compressor Start Up PPE: Safety mask, glasses, hearing protection and gloves. Ensure signage is in place.

308

STANDARD WORK PROCEDURE No: DIR 8.10 Prepared By: Vaughan Cullen Title: Pilot Hole Reaming Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

3 Prepare for pilot hole reaming. Personal injury. Manual handling.

Pinch points.

8 Moderate

Make up hammer by hand while piston case / body is in horizontal position (preferably at waist height) with check valve, choke, control tube, piston. Retaining bush, O ring / split ring, drive sub and a bit filled with the correct exhaust tube. Place hammer in perpendicular position, use winch and sling to lift any bits over B" diameter. NOTE: Particular attention should be paid to keeping hands or fingers clear of "pinch points" between drive sub and bit.

3 Low

4 Lifting hammer. Personal injury. Manual handling.

Pinch points.

13 Moderate

Screw lifting plug on to hammer top sub by hand. Attach winch rope clevis or lifting device to lifting sub. At no time shall any body part come between the moving hammer and any stationary object. Ensure work area / platform is free of obstructions and grease bucket and stilsons are ready to go.

6 Low

5 Pick up can winch line Personal injury. Manual handling.

Pinch points.

13 Moderate

Pick up on winch line and raise hammer to vertical position ensuring clean lift and path for hammer. Note: Do not lock fingers together behind hammer body or bit. Driller's Assistant should control slide of hammer utilising webbing rope strap. At no time shall any body part come between the moving hammer and any stationary object. Ensure hands / fingers do not come between hammer body and mast structure during lifting procedure.

6 Low

6 Lower hammer bit into slips table and insert.

Personal injury. Manual handling.

Pinch points.

13 Moderate

Lower hammer bit in to slips table and insert. Be aware of potential pinch points. Unscrew lifting sub and remove. Conduct Pre—start inspections Correct use of hand tools. Check all parts of the lifting assembly. Replace as necessary. Ensue lifting gear is tagged and in service, replace as necessary. Communication and training in the task. Never stand under suspended load PPE: Gloves


SWP SURGEN 2.03 Hiab Operation

6 Low

309

STANDARD WORK PROCEDURE No: DIR 8.10 Prepared By: Vaughan Cullen Title: Pilot Hole Reaming Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

7 Make up joint. Personal injury. Rotating equipment. Lifting.

13 Moderate

ADITC Competencies

PPE: gloves, eye protection

All personal shall stay well clear of any rotating equipment. Use slow rotation force to tighten threads to correct make up torque (ensure torque limit level is set). Remove spanner. SWP SURAIR 3.11 Setting Rotation

6 Low

8 Test hammer. Personal injury. Manual handling. 8

Moderate

ADlTC Competencies. Place "solid" wooden block on ground surface below hammer bit and slowly lower hammer on to block until bit closes on drive sub. Open compressor air lines and observe operation of hammer for a few seconds.

Warning: DO NOT use excessive air when testing hammer on wooden block. Close compressor airline, raise hammer and remove wooden block. PPE: Safety mask, glasses, hearing protection. Ensure signage is in place. Ensure no personnel near work area.

3 Low

9 Start drilling. Personal injury. Rotating equipment. Lifting.

13 moderate

Lower hammer to ground surface and open compressor airline and water line to hole collar. Check hammer oiler is on and functioning. Commence drilling until top of assembly is at slips table. PPE: Safety mask, glasses, hearing protection. Ensure signage is in place. Ensure no personnel near work area. SWP SURAIR 3.11 Setting Rotation READ SWP SURDIR 8.09 PILOT BREAKTHROUGH DRILLING

6 Low

WARNING

310


No: DIR 8.10 Prepared By: Vaughan Cullen Title: Pilot Hole Reaming Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

10 Break through Equipment damage. Equipment lost/ jammed in hole

20 High

READ SWP SURDIR 8.09 PILOT BREAKTHROUGH DRILLING. Once breakthrough depth is achieved — trip rods and hammer out of hole. Note: When breakthrough is imminent make sure that hammer and bottom hole assembly fully extended. Conduct Pre—start inspections Correct use of hand tools. Wear gloves. Check all parts of the rod handling assembly. Replace as necessary. Ensure the clamshell is the correct size for the rods that are in use Ensue lifting gear is tagged and in service, replace as necessary. Communication and training in the task. Never stand under suspended load

7 Moderate

WARNING

311


No: 200DGEN10.01 Prepared By: Vaughan Cullen Title: Setup head Rod UDR 200D Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Screw water swivel onto 6m head rod Manually lifting water swivel – back and/or hand injury Slip, trip, fall

17 Significant

Ensure correct lifting procedure used Wear gloves Ensure work area is clear of any trip hazards

5 Low

2 Torque thread up with stilsons Swivel back off. Stilsons slipping – abrasions/crush/contusion

18 Significant

Make sure all threads are tight. Ensure stilson jaws are clean, in good condition and Adjust Correct. Follow SWP Stilson Use

5 Low

3 Attach hoist rope to water swivel bail and hoist up mast above chuck

Hose getting caught – equipment damage Pinch points

17 Significant

Ensure safety clip has been placed in clevis pin Gloves to be worn

3 Low

312


No: 200DGEN10.02 Prepared By: Vaughan Cullen Title: Setup to Run Survey UDR 200D Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Stop rotation — break core off bottom. Pull rod string up with head. Close foot clamp jaws. Unscrew head rod

Pressurised water spray Equipment damage, rod drop

18 Significant

Follow standard operations procedure. Open vent valve prior to unscrewing threads. Foot clamp jaws to be clean and full closed

6 Low

2 Rack head to fully out position. Move plug slide into position.

Equipment damage. Hose caught in mast

17 Significant

Rack head completely out. Observe hose prior to moving head. Correct position, wear gloves to handle over-shot and inner tube

6 Low

3 Use winch to pull out 6m of rod. Lock foot clamp jaws onto rod string at correct position. Pull Tube

Equipment damage, rod drop Manual handling of over—shot, pinch points, burs on wire line

20 Significant

Ensure hoist plug thread is in good condition and clean. Ensure wire line is not caught on any obstruction. Pull Tube as per SWP

6 Low

4

Use 36" Break out stilsons to break thread. Unscrew thread. Lift 6m rod clear of thread, move rod to side of slide. Leave suspended on winch rope

Back strain Slip, trip, fall

Manual handling

25 High

Stilson jaws to be clean, in good condition and adjusted correctly. Follow S\/\/P Stilson Use Work area to be clean and clear of hazards Gloves to be worn

4 Low

5 Run survey equipment Follow standard operation procedures

313


No: 200DGEN10.03 Prepared By: Vaughan Cullen Title: Changing Chuck Jaws and Guide Brushes Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Turn rig off

2 Isolate rig

3 Remove retaining guide bush Personal injury 10

Moderate Correct PPE 4

Low

4 Returning Retaining ring Personal injury 12

Moderate CORRECT PPE 3

Low

5 Remove jaws Personal injury 12

Moderate

CORRECT PPE CORRECT Manual Handling

4 Low

6 Replace with jaws to suit Personal injury 12

Moderate


4 Low

7 Replace retainer Ring Personal injury 12

Moderate


4 Low

8 Open and close Chuck to check it is opening and closing correct

Personal injury Equipment damage

17 Significant

Hands away from chuck during this operation. Ensure chuck is opening correct. (damage to rods could occur).

4 Low

9 Put guide push cover on to suit jaws Personal injury 10

Moderate CORRECT Manual Handling 4

Low

10 Change top guide bush to suit jaws. CORRECT Manual Handling 12

Moderate


4 Low

314


No: 200DGEN10.04 Prepared By: Vaughan Cullen Title: Setting up Guards, Rails and No-Go Zones UDR 200D Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Check drill site has been prepared No Person to be allowed on Drill site Unless inducted

2 Check for overhead power lines, overhanging trees, possible underground cables

Personal injury – falling objects — electric shock

24 High

Remove overhanging branches or move rig if permitted Obtain permits regarding overhead cables and underground

4 Low

3 Setup rig Manual handling Slip, trip, fall Personal injury

23 High

Follow correct manual handling procedures. Good housekeeping, ensure trip hazards are removed Wear appropriate PPE – Gloves

12 Moderate

4 Lift all Hand Rails in to place; these include Guarding around main and wireline winches. Rod spin cage

Manual handling Pinch points

23 High

Follow correct manual handling procedures Gloves to be worn

17 Moderate

5

Ensure that rod sloop has been placed close enough to Drill Rig work platform so there is a minimal of manual Handling

Equipment damage — rod sloop hitting drill rig Manual handling Hand injury – splinters

23 High

Ensure that there is a spotter to guide the rod sloop as close to the rig as possible Follow correct lifting procedures Gloves to be worn Timbers to be securely placed and ensure they do not create

17 Moderate

6 Place rig Access Steps and Ladders into position

Manual Handling 20

Significant Correct lifting procedures 13

Moderate

7 Erect No—Go barricades, Fencing and signs around rigs rod work areas

Manual handling Slip, trip, fall

20 Significant

Fencing to be 9-12 metres from Rod Handler Good Housekeeping, ensure site is clean and all trip hazards are removed Use Hazob forms.

8 Moderate

8 Never allow anybody into No—Go Zones.

Personal injury 25

High

Ensure all signs are clearly visible, clean and in good condition. All signage MUST be obeyed Rig Inductions must be completed before allowing any person on site.

18 Significant

315


No: 200DGEN10.05 Prepared By: Vaughan Cullen Title: Kelly Rod & Drilling on UDR 200D Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Place water swivel on Kelly Rod Lifting Water Swivel. Personal Injury. Slips Trips Falls

17 Significant

Correct Manual Handling. Correct PPE. Correct Housekeeping

4 Low

2 Screw Swivel into Tool Joint hand tight.

Slips Trips Falls. Pinch Points

14 Moderate

Correct Housekeeping Correct PPE.

4 Low

3 Torque up Joint with Stilsons Personal Injury 9

Moderate Follow Correct SWP Stilson Use 4

Low

4 Place Kelly Hose on Swivel and tighten up

Slips Trips Falls. Pinch Points

17 Significant

Ensure good footing Use correct tools. Correct Housekeeping

4 Low

5 Get main winch rope and attach to water swivel bailer.

Slips Trips falls Property Damage

17 Significant

Correct Housekeeping Observation - Ensure Assistant is used as spotter and that winch rope or Kelly hose dose not get caught up or foul anywhere,

4 Low

6 Hoist Kelly Rod and water swivel above head of rig.

Slips Trips falls Property Damage

17 Significant

Correct Housekeeping Observation - Ensure Assistant is used as spotter and that winch rope or Kelly hose dose not get caught up or foul anywhere,

4 Low

7 Lower Kelly Rod into tool joint whilst assistant guides into place.

Cuts Pinches 10

Moderate

Wear gloves.

Handle Rod above where burs usually exist.

4 Low

8 Screw up rod by hand Cuts Pinches 10

Moderate

Wear gloves.

Handle Rod above where burs usually exist.

4 Low

9 Torque up with stilsons. Slips Trips Falls Pinch Points

17 Significant

Ensure good footing Use correct tools Correct Housekeeping Follow SWP Stilson Use

8 Moderate

316


No: 200DGEN10.05 Prepared By: Vaughan Cullen Title: Kelly Rod & Drilling on UDR 200D Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

10 Turn water on flush hole.

11 Use head to lower rod close to bottom of hole.

Equipment damage 17

Significant

Ensure to take weight of rods. Lower carefully to eliminate damage to bit and rod string.

4 Low

12 Run head up for stroke to start drilling, Close chuck jaws.

Pinch points 7

Moderate Ensure all personnel are clear before running head up 4

Low

13 Close Spin Guard and continue to Drill Pinch points 7

Moderate Wear correct PPE 4

Low

317


No: 200DGEN10.06 Prepared By: Vaughan Cullen Title: Removing Kelly Rod Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Take up strain on winch rope. Open Water Relief Tap

Equipment Damage Shock Load Stored energy

18 Significant

Take Strain before opening clamp. Ensure to relieve Pressure

4 Low

2 Open Chuck Jaws No Hazards Found

3 Open feet Clamps Personal Injury Crush Injury

18 Significant Ensure all personnel are clear of Clamp before operating

3 Low

4 Full Kelly rod until join is between Head and feet clamps.

Personal injury Equipment Damage

20 Significant

Look up and Live Assistant to act as spotters

5 Low

5 Close feet clamps allow strain off winch rope

Equipment damage Rods slipping

18 Significant Ensure clamps are clean and correct size

4 Low

6 Crack rod with breakouts unscrew by hand.

Personal injury

Pinch Points

16 Significant

Correct PPE Correct Stilson Use as per SWP

2 Low

7 Lift Kelly Rod out of head with winch. Equipment damage 16

Significant

Assistant acts as spotter.

Look up and Live

3 Low

8 Lower to Rod sloop Whilst assistant Guides out and into places

Personal injury Equipment Damage 16

Significant

Correct PPE Assistant acts as spotter

3 Low

318


No: 200DGEN10.07 Prepared By: Vaughan Cullen Title: Pulling & Running Rods and Casing 200D Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Driller allows slack in winch rope so assistant can unscrew hauling Plug

Personal injury 16

Significant Correct Manual Handling 4

Low

2 Driller takes up slack in rope and assistant screws into next rod. To repeat steps.

Personal injury 6

Low PPE 2

Low

3 When Putting Rods. Assistant screws hauling plug into rod on sloop or Truck or rod rack.

Personal injury 16

Significant Personal injury 4

Low

4 Driller lifts Rod with winch above tool clamps opens clamps and lowers into hole.

Equipment damage 18

Significant Assistant Guides Rod or casing Into Hole 3

Low

5 Driller closes foot clamps slackens winch rope and assistant unscrews by hand.

Personal injury 18

Significant

Correct Manual Handling PPE Ensure Personnel are clear of Clamps when operating

3 Low

6 Assistant then screws hauling plug into next rod

Personal injury 16

Significant

PPE Correct Manual Handling

4 Low

7 Driller hauls up rod with winch rope assistant guides rod into rod in clamp


19 Significant

Guide Rod carefully

Look Up and Live

6 Low

8 Assistant then spins rod into rod in clamp and tightens up with stilsons. Repeat steps until all rods are in hole.

Personal injury 16

Significant

PPE Correct Manual Handling

4 Low

9

Should casing be used ensure to flush hole to seat casing. Use Shoe bit if required. Follow SWP SURDIA 5.01

319


No: 200DGEN10.07 Prepared By: Vaughan Cullen Title: Pulling & Running Rods and Casing 200D Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

Remove Kelly Rod from Head following SWP No 2OODGlEN10.06

10 Bring in winch rope with hauling plug attached.

Pinch Points 9


Low

11 Drillers assistant Screws hauling plug into Rod

Pinch Points 9


Low

12 Driller takes up slack and strain on winch rope.

Equipment damage Shock Load

9 Moderate Take strain on winch

5 Low

13 Open foot clamps enough to pull rods up 6M or 3M so join is in correct place to crack with breakouts.

Personal injury Crushing

10 Moderate

Ensure all personnel are clear of foot clamps when operating

4 Low

14 Close foot clamps allow winch rope slacken off.

Personal injury Crushing

10 Moderate

Ensure all personnel are clear of foot clamps when operating

4 Low

15 Bring in breakouts and crack joint. Pinch Points 9


Low

16 Unscrew rod with stilsons then spin rod off by hands

Pinch Points 9

Moderate

PPE Correct Stilson Use

6 Low

17 Raise rod with winch to clear rod in clamp

Equipment damage Denting Rods

18 Significant Ensure to raise high enough above rod in clamps

5 Low

18 Assistant guides rod out onto rod sloop or truck or rod rack


19 Significant

PPE Assistant to guide rod out until located into position

6 Low

320


No: 200DGEN10.08 Prepared By: Vaughan Cullen Title: Raising Mast and Connect Stay Rods Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Lower Jack Legs on to Solid bed logs. Level Rig

Personal injury 12

Moderate Correct Manual Handling 4

Low

2 Raise Mast to vertical Position in a smooth motion.


17 Significant

Check mast for loose objects.

Look Up and Live (POWER LINES)

5 Low

3 Undo Stay Rods from Side of Mast Pinch Points Personal injury

12 Moderate

Correct PPE Correct Manual Handling

4 Low

4 Lower Mast until Stay Rods hang over Locking position. Pins to be put in.

Pinch Points Personal injury

9 Moderate

Correct PPE Correct Manual Handling

4 Low

5 Set Mast at correct Angle. Equipment Damage 17

Significant

Assistant to act as spotter. Look up and LIVE

5 Low

6 Dump Mast onto Bed Logs Equipment damage Personal injury

17 Significant

Ensure Bed Logs are firmly in place. Correct Manual Handling

5 Low

7 Locate pins into Mast Stays adjust by turning inner cylinders to get holes to line up

Personal injury 17

Significant

Correct Manual Handling Procedure

DO NOT PUT FINGERS IN HOLES TO CHECK ALLIGNMENT.

5 Low

8 Ensure to replace retaining pins Equipment damage Pins dropping out no support on mast

17 Significant CHECK PINS

5 Low

9 Lowering Mast Equipment Damage 17

Significant

ENSURE DUMP IS COMPLETELY UP BEFORE LOWERING MAST

5 Low

321


No: 200DGEN10.09 Prepared By: Vaughan Cullen Title: Adding 3m Rod Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Ensure Tool Joint is just above Foot clamps

2 Close Foot clamps. Crush Injury 7

Moderate

Correct PPE Ensure all personnel are clear of clamps before operating

4 Low

3 Turn water off and release pressure Stored Energy Personal Injury

18 Significant Ensure to release Pressure

4 Low

4 Undo Tool joint with head leaving head engaged

5 Traverse head to top of stroke. Equipment Damage 17

Significant

Observation – Ensure Assistant acts as Spotter and that Kelly hose does not get caught up or fouled anywhere.

4 Low

6 Pick up 3m rod place in bottom tool joint and screw in by hand.

Personal Injury Equipment Damage

18 Significant

Correct PPE Correct Manual Handling Ensure rod is placed into bottom joint correctly

6 Low

7 Lower head rod into added 3m rod and torque up.

Equipment Damage Personal Injury

19 Significant

Correct alignment of rods Correct PPE Correct Manual Handling

3 Low

322


No: 200DGEN10.10 Prepared By: Vaughan Cullen Title: Changing Head Gear & Greasing Sheave Wheels Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 The head gear is not to be put into low until approval is given by the

Supervisor

2 Remove Lacking Pin and move gear leaver

Equipment Damage 17

Significant

Do not force leaver with anything but hand pressure. Do not use hammers or bars.

4 Low

3 Replace Locking Pin when gear is changed.

Equipment Damage 17

Significant Locking Pin stops Gears Clashing. 4

Low

4 Grease Sheave Wheels at top of mast when mast ls in lower position.

Personal injury 10

Moderate Ensure Good footing. Use an approved ladder. 3

Low

323


No: 200DGEN10.11 Prepared By: Vaughan Cullen Title: Pulling Rods through Heads. Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1

With Head in lowest position. Pull Kelly Rod back with main winch hold open chuck until Tool joint is between top of head and upper break out Clamp

Equipment Damage 17

Significant Ensure joint is in correct Position. 4

Low

2 Close Chuck Jaws. Allow the weight off the winch rope

Equipment Damage 13

Moderate Allow weight off winch rope ( SHOCK LOAD) 5

Low

3 Close Upper Break Clamp.

4 Rotate Head Forward to undo rod.

5 Lift rod with winch to clear rod in head. Assistant guides rod out unto rack or sloop.


12 Moderate

Wear correct PPE Ensure rod is clear to prevent damage to threads and rods

5 Low

6 As rod comes down assistant ensure to pull rod clear of head


17 Significant

Correct PPE (Look Up and LIVE)

Be sure rod dose not hit head of rig where it could damage.

6 Low

7 Change winch rope over from water swivel to hauling plug.

Personal Injury 9


Low

8 Driller lifts hauling plug above rod in head using winch Assistant guides plug and acts as spotter.


17 Significant

Correct Manual Handling Correct PPE (Look Up and LIVE Winch Rope could fail)

6 Low

9 Assistant guides plug into rod in head as driller lowers with winch.

Personal Injury 9

Moderate Correct PPE GLOVES 3

Low

10 Assistant then screws hauling plug into rod by hand. Driller takes weight on rod and proceeds to pull rods


17 Significant

Correct Manual Handling Correct PPE Take weight on rod to stop (SHOCK LOADING)

6 Low

324

STANDARD WORK PROCEDURE No: COALGEN 13.02 Prepared By: Vaughan Cullen Title: Use of Modified Backup Stilsons Tripping Rods Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Ensure offsider’s deck is clean and clear of trip hazards.

Personal Injury Slip / Trip 13

Moderate

Remove obstructions. SWP SURHSE 1.03 Housekeeping Work area

5 Low

2 Check that 48 inch breakout stilsons and modified 36 in stilsons are in good condition.

Personal Injury from worn stilsons 13

Moderate

Inspect stilsons hook / heels and handles replace if necessary. SWP SURGEN 2.19 Stilson Use SWP SURGEN 2.20 Using Breakout Stilsons SWP SURGEN 2.21 Repair Stilsons

5 Low

3 Extend breakout stilson to suit rod. Personal Injury 9

Moderate

Protector plate and handle on stilsons and signage is in place P.P.E. gloves and eye protection. Do not place hands on stilsons when ram extending or retracting SWP SURGEN 2.20 Using Breakouts

4 Low

4 Ensure 48 inch breakout Stilsons are adjusted correctly to suit rod.

Personal Injury 5

Moderate

P.P.E. Gloves 3-5 mm gap

1 Low

5 Place stilsons on the rod and take strain.

Personal Injury pinch points Slipping stilsons

9 Moderate

Must ensure handle is attached to stilson at all times and guarding is in place. Gloves and eye protection. Do not rest hands on stilson when making or breaking rods. Stand clear in case stilson slips and swings out Communication Slowly engage lever SWP 2.20 Using Breakout Stilsons

3 Low

6 Offsider removes hands from stilsons and stands back.

Personal Injury slip trip 13

Moderate

Remove any obstructions. Do not rest hands on stilson when making or breaking rods. Stand clear in ease stilson slips and swings out Communication SWP SURHSE 1.03 Housekeeping Work Area SWP SURHSE 1.04 Housekeeping Tools SWP SURGEN 2.20 Using Breakouts

6 Low

325


No: COALGEN 13.02 Prepared By: Vaughan Cullen Title: Use of Modified Backup Stilsons Tripping Rods Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

7

Driller then breaks the rod. Offsider to stand back while driller retracts arm to break thread

Personal Injury Stilson Injury

Engage lever slowly Remove any obstructions. Do not rest hands on stilson when making or breaking rods. Stand clear in case stilson slips and swings out Communication

1 Low

8 Offsider removes breakout stilsons. Driller retracts breakout arm

Personal Injury Pinch points P.P.E. gloves and eye protection. 2

Low

9 Driller undoes rod ensuring pin thread is located in box end.

Personal Injury Pinch points

10

Offsider backs up rod using modified 36 inch stilsons


Ensure good communication and look at positioning of stilsons and hands/fingers before engaging rotation P.P.E. gloves and eye protections

2 Low

11 Driller breaks top joint. Check top thread has not undone completely. Do not stand under / in line with rod.

12 Offsider removes modified 361nch stilsons.


P.P.E. gloves and eye protection. Communication SWP SURGEN 2.19 Stilson Use SWP SURGEN 2.20 Using Breakout Stilsons SWP SURGEN 2.21 Repair Stilsons

2 Low

WARNING

WARNING WARNING

326


No: COALGEN 13.03 Prepared By: Vaughan Cullen Title: Fuelling up Diesel Trailer Truck Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Pre-start Genset on tank trailer. Pre-start not conducted

SWP SURHSE 1.10 Vehicle Daily Inspection Pre-Start Book Only refuel in well ventilated areas. Ensure you have a clear area free from trip hazards as well as clear access and exit points. Fire extinguishers.

8 Moderate

2 Clean around fuel cap, then remove cape

Stored pressure. Spillage Slips and Trips. Personal injury

13 Moderate

Tank relieves pressure. Ensure work area is clean and tidy. Ensure correct P.P.E is worn, Glasses, gloves.

5 Low

3 Start up Genset.

4

TAGGING

Switch on power at Genset, ensuring power switch is off at switch boards

If switch left on, can cause pump overload, resulting in diesel spills. Environmental damage

13 Moderate

Familiarisation with equipment. (Switches.) Equipment tagged and isolation switches are operable As per inspection. Locate emergency shutoff button locations for fuel pumping prior to refuelling.

5 Low

5 Take extension lead with ON — OFF switch to trailer tank. Remove from bag provided

Check tagging is current

6 Uncoil fuel hose and remove dust cap. Fuel Spills Stored pressure Environmental damage

7 Moderate

Loosen dust cap to relieve pressure and make sure that hose is raised. Gloves

2 Low

7 Clean end of hose before placing in tank.

Fuel Spills Stored pressure Environmental damage

7 Moderate

Ensure absorbent matting is readily available Treat spills immediately and notify supervisor. Fuel pump needs to be maned at all times while refuelling

2 Low

WARNING

327

STANDARD WORK PROCEDURE No: COALGEN 13.03 Prepared By: Vaughan Cullen Title: Fuelling up Diesel Trailer Truck Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

Spill kit to be available Follow environmental clean up procedures. Hold hose upwards. Gloves

8 Open cap on supply tank.

9 Holding hose in trailer tank, switch on power to pump.

Fuel spill Environmental damage

5 Low

Ensure no ignition sources are present. Fire Extinguishers. Ensure hose is in tank correctly. Equipment tagged and up to date Switch in operable condition Ensure absorbent matting is readily available. Treat spills immediately and notify supervisor. Fuel pump needs to be manned at all times while refuelling Spill kit to be available Follow environmental clean up procedures Only refuel in well ventilated areas. Ensure you have a clear area free from trip hazards as well as clear access and exit points.

1 Low

10

NEVER LEAVE HOSE UNATTENDED

Fuel spill Environmental damage Personal injury

21 Significant

Do not leave unattended at any time Ensure absorbent matting is readily available. Treat spills immediately and notify supervisor. Fuel pump needs to be manned at all times while refuelling Spill kit to be available Follow environmental clean up procedures. Wash affected areas immediately. Apply an after work cream to the affected area. Refer to MSDS on Fuel PPE gloves and eye protection

1 Low

WARNING

WARNING

328


No: COALGEN 13.03 Prepared By: Vaughan Cullen Title: Fuelling up Diesel Trailer Truck Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

11 When tank is full, switch power off. Fuel spill Environmental damage

21 Significant

Do not leave unattended. Drain hose of fuel after switching off

1 Low

12 Remove hose from tank being careful not to spill any fuel. Replace dust cap

Fuel spill Environmental damage Personal injury

5 Low

Hold hose upwards whilst replacing dust cap. Ensure absorbent matting is readily available. Treat spills immediately and notify supervisor. Spill kit to be available Follow environmental clean up procedures. Wash affected areas immediately. Apply an after work cream to the affected area. Refer to MSDS on Fuel PPE gloves and eye protection

2 Low

13 Coil hose back up neatly

14 Replace cap on trailer tank.

15 Close tap on supply tank.

16 Place switch board back in bag provided and return to correct location.

17 Shutdown Genset. Improper shut down resulting in engine damage

4 Low Follow shut down procedures.

1 Low

329


No: COALGEN 13.05 Prepared By: Vaughan Cullen Title: Night Drilling Approved By: Employee Relations Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1

Cold Weather

EXTREME WEATHER CONDITIONS CAN CAUSE SERIOUS INJURY AND

POSSIBLY DEATH.

Personal Injury 2

Moderate

Inductions on appropriate clothing for extreme temperatures. Warm up exercises. Gloves. Wet weather gear. Appropriate clothing ; jeans, jackets and thermals SWP SURHSE 1.01 PPE

5 Low

2 Poor Visibility Personal Injury 8

Moderate

Clear safety glasses clean. Set up lighting plant correctly SWP SURGEN 2.22 Set up/Pull down Lighting Plant Conduct a site layout plan and adhere to it Conduct good housekeeping. SWP SURHSE 1.03 Housekeeping. Ensure all lights are working.

3 Low

3 Shadows Trips, slips, Personal Injury 12

Moderate

Clear safety glasses clean. Set up lighting plant correctly SWP SURGEN 2.22 Set up/Pull down Lighting Plant Conduct a site layout plan and adhere to it Conduct good housekeeping. SWP SURHSE 1.03 Housekeeping. Ensure all lights are working.

5 Low

WARNING

330

STANDARD WORK PROCEDURE No: COALGEN 13.06 Prepared By: Vaughan Cullen Title: Run Casing clamshell with Sling Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1

Adding casing This procedure is only to be used if it is physically impossible to run the casing without a hook. It has been implemented for use predominately in the GAS division.

2 Inspect condition of clamshell cable and sling

Damaged equipment, rod may drop -personal injury

18 Moderate

Check clamshell is not flared, cables in good condition, cable clamps fitted correctly. Sling is tagged and in a serviceable condition Sling has the correct load lifting rate Pre-start inspections

7 Moderate

3 Slide clamshell over rod and double yoke sling over rod

4 Move clamshell towards box end until cable and sling are tight.

5 Slowly lift rod with winch, drill assistant guiding rod.

Sling slips and falls out of rod. Rod catches on something causing it to kick out

21 High

Ensure connector cable is taught as per step 3. Lift rod slowly, and guide carefully, Ensure sling is secure ADlTC Competencies. SWP SURHSE 1.02 Manual Handling

7 Moderate

6

Align pin end of rod into box end of rod in clamps. Offsider holds out rod and driller lowers drive sub into rod box and slowly bring together.

Lifting rod to much, causing it to kick out. 20

High

Never stand in direct line with rod, stand to one side. Use head traverse lever to take up the bit of slack not winch gloves

4 Low

WARNING

331





RESIDUAL RISK SCORE

2

Moderate 5

Low

7

Loosen off winch and sling. Slowly engage forward rotation to do up thread two turns. Watch winch cable Lower sling and remove. Lower clamshell to a workable height to hold. Offsider holds clamshell central and cable in a position as not to get hooked up in rod.

Rod fall Personal Injury

20 High

ADITC Competencies. Ensure red is located top and bottom securely Never stand in direct line with rod, stand to one side. PPE: gloves and eye protection

8

Slowly engage forward rotation to do up thread Lower clamshell to a workable height to hold. Offsider holds clamshell central and cable in a position as not to get, hooked up in rod.

Rod cross threads, causing hook to spin – Personal Injury

23 High

Rotate slowly. Hold cable out of way Watch clamshell is not catching on rod Gloves ADlTC Competencies

8 Moderate

WARNING

WARNING

332





RESIDUAL RISK SCORE

9

Loosen off winch and sling. Once red is torqued to required pressure. Open clamps and lower rod. Close clamps and unscrew rod. Raise head and lift clamshell from rod

Rod drops – Personal Injury 24

High

Check rod ls done up before opening clamps. Watch winch cable and clamshell cl0n’t become caught up in lowering of rod. Gloves ADITC Competencies

12 Moderate

10 Repeat until .all casing is in the hole.

WARNING

333

STANDARD WORK PROCEDURE No: COALGEN 13.07 Prepared By: Vaughan Cullen Title: Cutting with Oxy Acetylene Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Inspect equipment

2 Unroll Oxy and Acetylene hoses Personal Injury, trips 8

Moderate Insure correct footing, when rolling out hoses. 3

Low

3 Turn on Oxy and Acetylene Personal Injury Blow out of casing

12 Moderate

Refer to HOT WORK PERMIT PROCEDURE and OXY/ACETYLENE. Hot work permit Safe location Fire extinguishers Spotter PPE: Shield and gloves, spark arrestor Competency and certification for the task

5 Low

4 Make sure object casing is in a suitable position.

Personal Injury Rolling casing

8 Moderate Insure casing has wedges under it to stop rolling.

5 Low

5

Light Oxy and Acetylene

RISK OF FIRE AND/OR EXPLOSION

Personal Injury – burns 12

Moderate

Hot work permit Safe location Remove item to be cut to the safest work environment possible, if this can’t be achieved and the risk of fire or explosion is possible reassess the task and contact a supervisor. Fire extinguishers Spotter PPE: Shield and gloves, spark arrestor.

5 Low

6 Cut Object Personal Injury – burns 8

Moderate

Hot work permit Safe location Fire extinguishers Spotter PPE: Shield and gloves, spark arrestor.

3 Low

7 When object has been cut Personal Injury – burns 8

Moderate

Safe location Fire extinguishers Spotter PPE: Shield and gloves, spark arrestor.

3 Low

WARNING

334


No: COALGEN 13.07 Prepared By: Vaughan Cullen Title: Cutting with Oxy Acetylene Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

Allow to cool, wear PPE gloves. Ensure no risk of fire

8 Turn off Torch Personal Injury, flash back 12

Moderate Wear PPE gloves. Insure of spark arrester 5

Low

9 Turn off Oxy and Acetylene Personal Injury, leaking hoses 8

Moderate Insure taps are turned off at bottles. 3

Low

10 Bleed off Hoses Personal Injury, inhale gas 8

Moderate Bleed off hoses in ventilated area. 3

Low

11 Pack up equipment Equipment damage 8

Moderate Check hoses do not get tangled. 3

Low

335


No: COALGEN 13.08 Prepared By: Vaughan Cullen Title: HAND TOOLS Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

Caution: A large number of injuries result from improper use of hand tools. Workplace injuries can include eye injuries from flying particles, strains and sprains due to slipping or defective spanners and wrenches, penetrating or stab wounds from sharp tools such as chisels or screwdrivers, etc.

1 Always inspect hand tools prior to use. Faulty Tools 8

Moderate

Pre—start inspections. Place out of service tag on faulty tools and report to your supervisor. Dispose of tools that are unrepairable.

2 Low

2 Use only tools that are in good condition and fit for the purpose for which they were designed.

Faulty Tools 8

Moderate

Pre—start inspections. Place out of service tag on faulty tools and report to your supervisor. Dispose of tools that are unrepairable.

2 Low

3 Ensure stilson jaws are in good condition. Do not use blunt or defective tools.

Slips – cuts and abrasions to hands 13

Moderate

Replace jaws on stilsons or remove from workplace and place out of service Refer to SWP SURGEN 2.21 Repair Stilsons.

8 Moderate

4 Ensure work area is clear and free from clutter.

Slips, trips and falls 18

Moderate

Good housekeeping — remember; if you use it put it back. SWP SURHSE 1.04 Housekeeping Tools

2 Low

5 Sharp edged or pointed tools should have the edge or point guarded if possible, when not in use.

6 Hammers, axes, shovels and similar tools must not be used if timber handles are loose, cracked or splintered.

Cuts and abrasions Faulty equipment

8 Moderate

Pre—start inspections Correct PPE Replace handle or remove from use

2 Low

7 Mushroomed heads of chisels, wedges, spikes, etc. must be replaced.

Eye injury, cuts and abrasions to hands and fingers

22 High

Pre—start inspections DO NOT USE – dispose of tool properly.

2 Low

336


No: COALGEN 13.08 Prepared By: Vaughan Cullen Title: HAND TOOLS Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

8

Use the correct type and size of spanner for the job. Putting a spammer is safer than pushing it. If it is necessary to push a spammer, keep your knuckles clear.

Hand injury. Cuts and abrasions

17 Moderate

Ensure correct size spanner is used and correct PPE is worn – gloves

4 Low

9 Never use a spanner or a wrench as a hammer.

Hand injury Damaged equipment

9 Moderate

Select the correct tool for the task. Correct PPE to be worn.

2 Low

10 Never apply a spanner or wrench to moving machinery.

Moving object

Crush injury

22 High

Isolate machinery and place out of service tag/personal danger tag before commencing work. Follow isolation procedures.

11 Do not strike hard faced tools such as hammers together — they can shatter

Use only copper hammers on site

12 Pass tools hand to hand – do not throw them,

Dropped tools

Personal injury

Equipment damage

8 Moderate

Don’t throw tools at all PPE

2 Low

13 Tools must be put away in their appropriate storage areas after use.

Trip Hazard 8

Moderate

Good housekeeping. SWP SURHSE 1.04 Housekeeping Tools

1 Low

Remember: Tools lying around the workplace constitute a hazard and contribute to poor housekeeping standards and possible injuries.

337

STANDARD WORK PROCEDURE No: COALGEN 13.09 Prepared By: Vaughan Cullen Title: REFUELLING PROCESS FOR FIXED AND Approved By: Vaughan Cullen MOBILE PLANT AND EQUIPMENT Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Notify other personnel of your intentions.

2

Be aware of all sources of ignition, e.g. exhaust turbo manifolds and

GAS well heads

Hydrocarbon fire 22

High

Ensure refuelling hose is not dragged across any possible ignition source. Ensure refuelling ls carried near ignition sources. Carry a LEL gas monitor if unsure.

13 Moderate

3

Position fuel tanker in a safe area that doesn’t effect emergency evacuation procedures or enhance the risk of explosion. Shut engines down prior to refuelling, ensuring the vehicle is securely parked and chocked.

Runaway Vehicle 19

High

Place fuel tanker on firm, flat level ground where possible. Place chocks under wheels to suit ground conditions. Ensure adequate signage is in place i.e.: Diesel on tanks Ask for assistance.

4 Low

4 Lock out equipment as per mine lock out procedure. (if applicable)

Incorrect isolation procedures 19

High Refer to SWP SURHSE 1.05 Isolation Lockout

5

Refuelling shall not take place in a confined space (fuming), ensure vehicle (fuelling car) is at a safe distance of 2 meters from fuelling point

Poor ventilation Trip hazards

19 High

Only refuel in well ventilated areas. Ensure you have a clear area free from trip hazards as well as clear access and exit points

3 Low

WARNING

WARNING

338





RESIDUAL RISK SCORE

6

Locate emergency shut off button locations for fuel pumping prior to refuelling Gas Drilling ensure a gas detector is present.

Hydrocarbon fire Gas explosion

22 High

You need to know the location of the emergency stop button before commencing to refuel. Make sure you test emergency stop buttons before hand. Fire Extinguishers

Check gas detector is operable and calibrated. Stop refuelling immediately if gas is detected and follow Gas Evacuation Procedures Refer to SWP COALGEN 13.04 SWP SURHSE 1.16 Emergency Gas Leak SWF SURHSE 1.18 Emergency Procedure Rig Fire.

7 Ensure the fuel delivery line does not come into contact with hot surfaces.

Hydrocarbon fire 22

High Suitable fire extinguisher to be in easy reach. 5

Low

8 No person shall remain in the vehicle during refuelling operations.

9 Do not leave fuel pumping into tanks unattended

Hydrocarbon spill Hydrocarbon fire

22 High

Treat spills immediately and notify supervisor. Fuel pump needs to be manned at all times while refuelling Spill kit to be available Follow environmental clean up procedures.

18 Moderate

WARNING

339





RESIDUAL RISK SCORE

10

Take care not to spill fuel. In the event of spillage, shut the supply off immediately clean up the spill using the spill kit. Report the spill to Supervisor.

Environmental damage 14

Moderate

Treat spills immediately and notify supervisor. Fuel pump needs to be manned at all times while refuelling Spill kit to be available Follow environmental clean up procedures.

8 Moderate

11 lf fuel is spilled on skin or clothing, thoroughly wash affected area and change clothing if possible

Allergic reaction.

Dermatitis.

13 Moderate

Wash affected areas immediately. Apply an after work cream to the affected area. Refer to MSDS on Fuel PPE gloves and eye protection

8 Moderate

12

Ensure fuel lines are drained then completely closed off, rolled up and bulk fuel supply is moved away from Rig / Compressor prior to start up or unlocking equipment

Hydrocarbon spill Hydrocarbon fire. Trip Hazard

18 Moderate

Ensure all taps are in the oft position. Hoses are to be neatly rolled up and stored. Move tanker a safe distance away from equipment.

5 Low

13 Restore equipment to working order as per lock out procedures.

Visually inspect tanks etc. before de—isolating.

Refer to SWP SURHSE 1.05 Isolation Lockout.

Note: Ensure all fuel caps are securely placed back on tanks before restarting equipment.

Caution: Beware of hazards associated with static electricity. Avoid entering your vehicle whilst refuelling, if you must enter the vehicle: ensure you exit the vehicle

WARNING

340





RESIDUAL RISK SCORE

Touching metal as you close the door, prior to removing the nozzle. This will discharge static electricity from your body and remove the risk of causing a spark

341

STANDARD WORK PROCEDURE No: COALGEN 13.10 Prepared By: Vaughan Cullen Title: Use of Pressure Chamber to Test Stand Pipes Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

1 Ensure standpipe base has been drilled through and a further 3 meters has been drilled past end of stand pipe.

2 Visually inspect pressure chamber for damage, cracks, worn threads and inspect relief valve is free and working.

Manual handling, splinters, hand injuries Very Low

Correct manual handling procedures as per SWP UNDHSE 1.02 wear correct PPE

Very Low

3 Recalibrate been pump relief valve to blew off at 100psi

Use of hand tools, hand injury Low Correct manual handling procedures as per SWP UNDHSE 1.02 ·

Very Low

4 Screw pressure chamber on to standpipe end use stilsons to tighten

Manual handling, hand injuries from stilsons

Low Correct manual handling procedures as per SWP UNDHSE 1.02 and correct use of stilsons as per SWP UNDHSE 1.16

Very Low

5 Attach pump down hose to inlet manifold on pressure chamber.

Hand injuries, splinters, pinch points Very Low

\/\/ear correct PPE i.e. gloves Correct manual handling procedures as per SWP UNDHSE 1.02 wear correct PPE

Very Low

6 Ensure taps to Kelly rod, pump down hose end relief valve on pressure chamber are open

Hand injuries, splinters, pinch points Very Low

\/\/ear correct PPE i.e. gloves Correct manual handling procedures as per SWP UNDHSE 1.02 wear correct PPE

Very Low

7 Engage bean pump to start water flow, ensuring flow rate is less than 20lt/per min

Hose failure if started at higher flow rate Moderate Follow previous steps, and ensure hose is in good condition Low

8

Once water runs fluently from relief valve on pressure chamber, close valve and move over to manifold where controls for Kelly rod and pump down hoses are

Pinch points on taps, manual handling Low Correct manual handling procedures as per SWP UNDHSE 1.02

Very Low

9 While monitoring gauge on pressure chamber slowly close off hose to Kelly rod

Personal injury – standpipe failure/blowout, hose failure

Very High No personnel to be within 3 meters of stand pipe, and/or in direct line of sight

Moderate

10 Watch stand pipe for signs of failure (i.e.) weeping around outside of pipe

Personal injury – standpipe failure/blowout, hose failure

Very High No personnel to be within 3 meters of stand pipe, and/or in direct line of sight

Moderate

342


No: COALGEN 13.10 Prepared By: Vaughan Cullen Title: Use of Pressure Chamber to Test Stand Pipes Approved By: Vaughan Cullen Revision Date: 12th October 2010 Reviewed By: Lawrie Lorrigan




RESIDUAL RISK SCORE

/burst

11 Once pressure reaches 100 psi according to gauge, and ensure casing holds pressure for 5 minutes.

Personal injury-hose failure, relief valve not venting

High

No personal to be with in 3 meters of stand pipe, and/or in direct line of sight. Ensure hose in good condition

Low

12 Stop bean pump, Open tap to Kelly rod releasing pressure from line and standpipe `

Hose under pressure, foreign particles being introduced to air

Moderate Follow previous steps, and ensure hose is in good condition Low

13 Remove pump down hose off of pressure chamber

Splinters from hose, pinch points Low Correct manual handling procedures as per SWP UNDHSE 1.02 wear correct PPE

Very Low

14 Remove chamber from standpipe using stilsons

Hand injury from hand tools manual handling

Low

Wear correct PPE i.e. gloves Correct manual handling procedures as per SWP UNDHSE 1.02 and correct use of stilsons as per SWP UNDHSE 1.16 wear correct PPE

Very Low

15 Clean, lubricate and store in dry place to keep free from corrosion.

Use of cleaning agents, manual handling Very Low Correct manual handling procedures as per SWP UNDHSE 1.02 wear correct PPE

343

SWP RPL ASSESSMENT RECORD

SURFACE RPL = Recognised Prior Learning CA = Competency Achieved *CAN = Competency Not

Achieved ASS: Assessor

RPL Participant ………………………………….Signature ……………………………………… Classification ……………………………………..Location ……………………………………….

SWPs Title Result Initials Date

ASS Assessed

SURHSE1.01 Personal Protective Equipment

SURHSE1.02 Manual Handling

SURHSE1.03 House Keeping Work Area

SURHSE1.04 House Keeping Tools

SURHSE1.05 Isolation Lock Out all Vehicles and Plant

SURHSE1.08 Shift Change Surface

SURHSE1.09 Cross Shift Hand Over

SURHSE1.10 Light Vehicle Daily inspection

SURHSE1.11 Truck Daily Check

SURHSE1.12 Pre Start Check List Surface

SURHSE1.13 Operate Salamander

SURHSE1.14 Chemical Handling

SURHSE1.15 Remote Travel & travel Between Sites

SURHSE1.16 Emergency Procedure Gas intersection

SURHSE1.17 Unpack New Rods

SURHSE1.18 Emergency Procedure Drill Rig Fire

SURGEN2.01 Acquire Equipment for Mobilization

SURGEN2.02 Refuel Diesels

SURGEN2.03 Hiab Operation

SURGEN2.04 Secure Load Site Move

SURGEN2.05 Site Move Surface

SURGEN2.06 Set Up Surface Rig

SURGEN2.07 Raising Mast Wedge instructions

SURGEN2.08 Raising Mast UDR l000

SURGEN2.09 Raising Mast 45 to 66 Degrees

SURGEN2.10 Raising Mast 66 to 90 Degrees

SURGEN2.11 Lower Mast 66 to 90 Degrees

SURGEN2.12 Lower Mast 45 to 66 Degrees _

SURGEN2.13 Main Winch Operation UDR 1000

SURGEN2.14 Wire Line Winch Operation

SURGEN2.15 Ascending & Descending UDR Mast

SURGEN2.16 Climbing UDR Masts - UDR650

SURGEN2.17 Mixing Mud

SURGEN2.18 Using Marsh Funnel

SURGEN2.19 Stilson Use

SURGEN2.20 Using Break Out Stilson

SURGEN2.21 Repair Stilsons

SURGEN2,22 Setting Up Lighting Plant

SURGEN2.23 Set up lay down area

SURGEN2.24 Install BOP

SURGEN2.25 Test BOP

SURGEN2.26 Calculate Depth of Hole

SURGEN2.27 Loading ~ Unloading Rod Spinner

SURGEN2.28 Tramming UDR 650 Rig

344




RPL Participant ………………………………….Signature ………………………………………

Classification ……………………………………..Location ……………………………………….


ASS Assessed

SURAIR3.01 Compressor Safety SURAIR3.02 Compressor Start Up SURAIR3.03 KL Rod Handler SURAIR3.04 KL Rod Pull SURAIR3.05 Running RC Rods SURAIR3.06 Pulling RC Rods SURAIR3.07 Break Out Hammer SURAIR3.08 Remove & Replacing Hammer Bits SURAIR3.09 Assembly RC Hammer SURAIR3.10 RC Collar SURAIR3.11 Setting Rotation SURAIR3.12 RC drilling SURAIR3.13 Safe Handling of Blow Down Sub SURAIR3.14 Safe Handling of Blow Up Sub SURAIR3.15 Removing Sample Hose From Cyclone SURAIR3.16 Unblock RC Hose SURAIR3.17 Preventative Maint RC Sample Hose SURAIR3.18 RC Hose Fittings

SURAIR3.19 Cleaning Dust Suppression Unit SURAIR3.20 Drill Clean Dust Collector Maintenance

SURAIR3.21 Running Tubex Casing SURAIR3.22 Pulling Tubex Casing SURAIR3.23 Injecting Mist or Foam SURAIR3.24 Back Hammer SURMUD4.01

SURMUD4.02 SURDIA5.01 Run Casing Start of Hole

SURDIA5.02 Lower Core Barrel & Rods SURDIA5.03 Setting Hold Back, Pull Down Micro Feed SURDIA5.04 Setting Rotation

SURDIA5.05 Diamond Drilling SURDIA5.06 Use Of Power Stilson

SURDIA5.07 Core Tube Recovery SURDIA5.08 Empty Core Tubes

SURDIA5.09 Pumping Out Splits

SURDIA5.10 Correct Core Presentation SURDIA5.11 Pulling & Running Q Series Rods

SURDIA5.12 Pull & Run Rods Using Rod Stack Bar- Rods in mast. SURDIA5.13 Rod Vibrations Dry Hole

SURDIA5.14 Rod Vibration Bent Rods SURDIA5.15 Rod Vibration Rig Off Line SURDIA5.16 Lost Circulation

SURDIA5.17 Add Remove 6m Rods with Clamshell SURDIA5.18 Differential Stick

SURDIA5.19 Stuck Rods

345







ASS Assessed

SURDIA5.20 Stripping Bits SURDIA5.21 Assemble Q Series Outer Barrel

SURDIA5.22 Assemble Q Series Inner tube SURDIA5.23 Assemble Q3 Series Inner Tube

SURDIA5.24 Adjust Length Q Series Inner Tube SURDIA5.25 Assembly of Universal Water swivel SURDIA5.26 Changing Over Shot lifting Dogs

SURDIA5.27 Mount & Dismount Work Platform SURDIA5.28 Change Q Series Back End Parts

SURDIA5.29 Core Orientation With Pencil Tip Spear SURDIA5.30 Core Orientation Van Ruth

SURDIA5.31 Pump Water Supply

SURDIA5.32 Cutting Casing SURDIA5.33 Cutting Wire Line At Surface

DlR8.01 Navi Drill Pre Check DlR8.02 Down Hole Motor

DlR8.03 Down Hole Motor Navi DlR8.04 Navi Drill Orientation DlR8.05 Steer Tool Survey

DlR8.06 Communication of Break Through DlR8.07 Pilot Hole Break through

DlR8.08 Break Through Drilling DlR8.09 Break through Drilling DlR8.10 Pilot Hole Reaming

DlR8.11 Back Hammer DlR8.12 Hall Rowe Wedge

MAINGEN6.00 Change & Repair Hydraulic Hose MAINGEN6.01 Change Hydraulic Pressure Gauge

MAINGEN6.02 Change Balls & Seats Bean Pump

MAINGEN6.03 Replace Plunger Packing Bean Pump MAINGEN6.04

Overhaul Relief Valve

MAINGEN6.05 Fitting Cable Clamps MAINGEN6.06 Replace alternator on Diesel Engine

MAINGEN6.07 Replace Starter Motor On Diesel Engine MAINGEN6.08 Replace “V” belt on Diesel Engine MAINGEN6.09 Replace Water Hose On Diesel Engine

MAINGEN6.10 Charging 12 Volt Battery MAINGEN6.11 Jump start 12 Volt System

MAINGEN6.12 Jump start 24 Volt System MAINGEN6.13 Vibration noise From Head – Transmission

MAINGEN6.14 Light Vehicle Daily Inspection

MAINGEN6.15 Truck Daily Check

MAINGEN6.16 Remove Flat Tyres – Light Vehicles

MAINGEN6.17 Remove Flat Tyres - Trucks MAINGEN6.18 Remove Flat Tyres - Trucks

346







ASS Assessed

FORGEN12.01 Placing Stabiliser onto Rod Handler

FORGEN12.02 Install BOP

FORGEN12.03 Test BOP

FORGEN12.04 Back Hammer

FORGEN12.05 Pilot Hole Reaming.

FORGEN12.06 Pilot Hole Reaming.

FORGEN12.07 Pulling Rods

FORGEN12.08 Rig Setup

FORGEN12.09 Running Rods

FORGEN12.10 Pilot Hole Break Through

COALGEN13.01 Install of Washington Rubber

COALGEN13.02 Use of Modified back up stilsons tripping rods

COALGEN13.03 Fuelling up Diesel Trailer Tank

COALGEN13.04 Gas Leak instruction Procedure

COALGEN13.05 Night Drilling

Refer SURAIR 3.03 KL Rod Handler

COALGEN13.06 Spudding in First Rod

COALGEN13.07 Cut Casing with Oxy Acetylene at Lay down area. COALGEN13.08 Installing Steel Casing

347

RISK ASSESSMENT

Severity/Consequences Table

Rating Injury Severity Environment Damage Collateral damage

1 Fatality, Loss of limb, Blindness,

Electrocution, Permanent Health Effects Permanent and irreparable

damage to environment More than $500k damage

2 Major injury — Serious lost time injury

more than 7 days Major but repairable damage

to environment $100 -$500k damage

3 Severe injury — fractures, Short term lost

time injury

Severe impact on environment requiring

significant time to rectify $50 -$100k damage

4 Requires Medical Treatment Severe impact on

environment but easily rectified.

$5 -$50k damage

5 Repeat first aid treatments Minor impact on

environment/property Under $5k

Probability Table

Probability Rating Estimate of Incident Frequency

Common/Frequent A Incident likely to occur frequently (i.e.. daily, weekly, monthly) Occasional B Incident likely to occur occasionally Remote C Incident could occur Improbable D Incident unlikely to occur Practically impossible E Very unlikely to occur

Calculator

Probability

C o n s e q u e n c e s

A B C D E

1 25 24 22 19 15

2 23 21 18 14 10

3 20 17 13 9 6

4 16 12 8 5 3

5 11 7 4 2 1

Colour Code Extremely High Risk Significant Risk Moderate Risk Low Risk

Risk Score between 11 – 25 requires a JSA prior to commencement of job

Documents

STANDARD WORK PROCEDURE...202 STANDARD WORK PROCEDURE No: SURDIA5.01 Prepared By: Vaughan Cullen Title: Running/Pulling and Seating Approved By: Vaughan Cullen Casing and the Start