Safe Work Instruction

Transcription

1 Safe Work Instruction Version 4 (10 January 2012) Status: Approved Site: Department: GOONYELLA RIVERSIDE Mobile Maintenance PPE Required Job Step Analysis reference Document Attached BMA Standard reference GRM SOP Safe Operation and Movement of Vehicles 010 GRM SOP Isolation & Tagging Additional Hazard Considerations Other Relevant Information RIISAM210A RFW Wheel Assembly (KM# ) Mine Traffic Rules, GRM-HSE-PRO-0113 Mandatory - Pre-start Actions Required permits Complete BMA Safe Conduct work area inspection Required permit number: Personal Isolation Multi Lock Isolation Required permit number: Relevant OEM instructions & Specification available Required permit number: People, Equipment, Materials and Tools Required People Equipment Materials & Tools Maintenance Fitters/ Servicemen/ Tyre Fitters Personal Locks Danger tags Minimum 1 x Spotter/ Controller Barricade/ Barrier/ Sign Intermittent Operation tags EXPECTED JOB DURATION: Hours: Shifts: READ THIS ENTIRE DOCUMENT BEFORE PROCEEDING -DOCUMENT TO BE REVIEWED AND SIGNED OFF BY ALL TEAM MEMBERS CONDUCTING TASK AND SUPERVISOR BEFORE COMMENCING TASK. -IF CONDITIONS OR ENVIRONMENT CHANGE, OR YOU ARE UNSURE ABOUT ANY ASPECTS OF THIS SWI STOP AND CONTACT YOUR SUPERVISOR Uncontrolled when printed Page 1 of 10

2 Heavy Equipment Entering the Workshop 1. Inspect for Loads if Applicable 1. Rear Dumps a. Raise body of truck and using a spotter look into the body from the side, a safe distance from the truck and check it is empty. b. If load is present return machine to production to remove any excess load or hang-up 2. Water Trucks c. Open drain valve in a suitable area (Wash-Pad) to remove possible water from the tank. 3. Service Trucks d. Check level gauges and check for its level. If required evacuate excess fluids 4. Front End Loaders/Cable Reeler e. Inspect the bucket or reeler for load. If load is present return machine to production to remove any excess load or hang-up 5. This will ensure the machine weight is within the OEM recommended jacking SWL. Identify actual weight before jacking machine. 6. If a load is unable to be emptied or confirmed empty, a RISK ASSESSMENT and a JSA shall be done under Supervision. 7. Use 3 point contact where required when accessing and egressing equipment. 8. Ensure any load or part load on/in the machine is dumped or removed in an appropriate place before coming into the work area Warning Rear Dumps- Pre-Strip and Coal o Loose material on decking or in load carrying compartment, un-even, wet, Loads shifting. Unknown weight, hang-ups Water Trucks o Wet Slippery Surfaces. Large volumes of water. Unknown weight Service Trucks Uncontrolled when printed Page 2 of 10

3 o Wet Slippery Surfaces, Level Gauges not working. Unknown weight, Fluid under Pressure Front End Loaders/Cable Reeler o Hang-ups o Cable 2. Move Machinery into Workshop/Area 1. Ensure work area is clear of all obstacles and personnel before moving machinery into workshop/area 2. Hearing protection where required 3. Minimum of 1 x Spotter used to guide machine into position. In limited or restricted spaces, multiple Spotters may be necessary. a. Designate one Spotter as Controller. b. Multiple Spotters to stay in view of each other and control movement near the danger area. 4. One Spotter shall be visual to Operator at all times. 5. Use a competent operator at all times to move machine 6. Observe Industrial area traffic flow and Mine Site Traffic rules 7. When moving the machine (forward or reverse) in the workshop, 8. Operator to maintain slow, controlled movement at all times, drive to conditions 9. Mirrors to be cleaned and adjusted to ensure maximum vision for the operator at all times Warning 3. Secure machine Moving machinery Other personnel & equipment and infrastructure Noise Restricted work area Limited vision Excessive speed/movement Ground Conditions 1. Ensure machine is secured correctly as per GRM-HSE-PRO-0113andSOP Machinery to have a. Park Brake applied b. Wheels Chocked if applicable c. Implements lowered to ground if applicable (place floor protection plates under contact points). d. Articulation locks to be fitted if applicable 3. Observe correct Manual Handling Techniques 4. If the equipment must be running to perform the task, then an Intermittent Operations Tag shall be used. A BMA Safe risk assessment shall also be completed in compliance with SOP-010 (Section 7.2.7) Uncontrolled when printed Page 3 of 10

4 5. Barricade and/or sign post as necessary Hazards Isolation Where equipment is not required to be running to perform task, it shall be shut down and isolated using personal locks and danger tags and tested for dead. (Refer SOP-010 Isolation and Tagging) Warning Slippery surfaces Other personnel interacting in area Uncontrolled Movement Manual Handling 4. Moving machine out of workshop/area 1. Carry out a walk-around inspection of machinery & area 2. Follow start-up procedure as per Mine Traffic Rules 3. Spotter shall give clear signal to Operator that it is safe to proceed, prior to machine being moved 4. Hearing protection where required- PPE 5. Minimum of 1 x Spotter used to guide machine into position. In limited or restricted spaces, multiple Spotters may be necessary. a. Designate one Spotter as Controller. b. Multiple Spotters to stay in view of each other and control movement near the danger area. 6. One Spotter shall be visual to Operator at all times. 7. Use a competent operator when moving the machine (forward or reverse) in the workshop, 8. Mirrors to be cleaned and adjusted to ensure maximum vision for the operator at all times Hazards Moving machinery Other personnel & equipment and infrastructure Constricted area Limited vision Excessive speed/movement Noise Uncontrolled when printed Page 4 of 10

5 5. Park machine on go-line 1. Competent Operator to access the go-line following correct Mine Site and Industrial area traffic flow rules 2. Ensure machine is secured correctly as per GRM-HSE-PRO-0113andSOP Machinery to have: a. Park Brake applied b. Wheels Chocked if applicable c. Implements lowered to ground if applicable d. Observe correct Manual Handling Techniques Hazards Other equipment/vehicles & personnel Uncontrolled movement Manual Handling 6. Additional Comments 1. Any changed conditions shall require a review or establishing of a JSA. (Any changes may require amendment to SWI) 2. This Safe Work Instruction shall be used when moving heavy machinery in and out of workshops/areas when being moved for maintenance/servicing 3. A minimum of 1 x Spotter shall be used to guide the machine into position. In restricted or limited space, multiple Spotters may be required to provide 360 visual. One spotter shall be designated as a Controller. If Spotter is not visible by the machine Operator, the Operator shall stop the machine 4. Work area shall be cleared of all obstacles before moving machinery in and out of workshop/areas 5. Where Spotter is required to control passing traffic and whilst machine is reversing they shall be positioned at rear of equipment 6. Workshop spoon drains are NOT designated V drains or sufficient for chocking Uncontrolled when printed Page 5 of 10

6 Task Review and Sign Off Name Signature Position Date Name Signature Position Date Supervisor Supervisor Identified items to be added/removed from Work Instruction Location Description e.g. 7.1 e.g. Include updated bolt tension of 45ft/lbs. Uncontrolled when printed Page 6 of 10

7 JOB STEP ANALYSIS FOR TASK OR PROCESS DESCRIPTION OF TASK/PROCESS/SYSTEM: Moving Heavy equipment in and out of the workshop WHAT CHANGE/ACTION IS BEING PROPOSED? RISK ASSESSMENT SCOPE: ASSESSMENT CONDUCTED BY: Brian Donohoe, Eric Abbott, Broderick Tallar, Dane Schuurman DATE: ASSESSMENT REVIEWED BY: DATE: ITEM N o 1 JOB STEP OR ACTIVITY Inspect Machine for load and cleanliness POTENTIAL HAZARDS OR ENERGIES Loose material in or on machinery Uneven or ground conditions Slippery surfaces EXISTING/CURRENT CONTROLS BMA Safe Inspect ground conditions 3 Point contact Spotter CONSEQUENCE INHERENT RISK RISK ANALYSIS LIKELIHOOD RISK RATING 1 D L ADDITIONAL/NEW RECOMMENDED CONTROLS CONSEQUE NCE RESIDUAL RISK RISK REVIEW LIKELIHOOD RISK RATING 2 Move machinery into workshop 3 Secure machine Moving machinery Other personnel & equipment and infrastructure Noise Restricted work area Limited vision Excessive speed/movement Slippery surfaces Manual Handling Uncontrolled movement BMA SOP Training Spotter Competent Operator Mine Traffic Rules PPE BMA SOP s Training 3 point contact GRM-HSE-PRO E M 2 E L Uncontrolled when printed Page 7 of 10

8 4 5 Moving machine out of workshop/area Park machine on goline. Moving machinery Other personnel & equipment and infrastructure Noise Constricted area Limited vision Excessive speed/movement Other equipment/vehicles & personnel Uncontrolled movement Limited vision Excessive speed/movement BMA SOP Training Spotter Competent Operator Mine Traffic Rules PPE BMA SOP s GRM-HSE-PRO-0113 Training Competent Operator Mine Traffic Rules V Drain for parking 3 E M 3 E M OVERALL RESIDUAL RISK RATING FOR TASK Moderate IF RISK RATING IS EXTREME OR HIGH - INFORM SAFETY ADVISOR IMMEDIATELY A CRITICAL ACTIVITY WORK INSTRUCTION SHALL BE REQUIRED Uncontrolled when printed Page 8 of 10

9 RISK ASSESSMENT TOOLS Uncontrolled when printed Page 9 of 10

10 THIS WORK INSTRUCTION FLOWCHART MINE MAINTENANCE SAFE WORK INSTRUCTION MOVING EQUIPMENT IN & OUT OF A WORKSHOP EQUIPMENT NEEDS MOVING IN/OUT OF A WORKSHOP COMPLETE TAKE 5 INSPECT EQUIPMENT FOR LOADS *Rear Dumps for loose material/ hang-up *Water Trucks for water *Service Trucks for combustibles GOONYELLA RIVERSIDE DOES EQUIPMENT CONTAIN LOAD? YES REMOVE LOAD NO REFER QC-PST 030 POSITION SPOTTER(S) & SAFELY MOVE MACHINE INTO WORKSHOP AREA PARK UP EQUIPMENT ON FLAT, HARD, LEVEL GROUND - SECURE MACHINE BY CHOCKS, V DRAIN, BRAKES - IMPLEMENTS LOWERED & PROTECTED ERECT BARRIER & SIGNS WHERE REQUIRED REFER QC-PST 010 ISOLATE MACHINE ATTACH PERSONAL LOCK & DANGER TAG TEST FOR DEAD WHERE REQUIRED FIT INTERMITTENT OPERATIONS TAG CARRY OUT TASK, MAINTENANCE SERVICING AS REQUIRED REMOVE TAGS & LOCKS & RE-ENERGISE REMOVE ANY BARRIERS/SIGNS ALLOCATE APPROPRIATE SPOTTERS REFER MINE TRAFFIC RULES CONDUCT WALK-AROUND INSPECTION OF MACHINE & AREA, FOLLOW START-UP PROCEDURES SPOTTERS TO SIGNAL SAFE TO MOVE SAFELY MOVE MACHINE OPERATOR TO DRIVE MACHINE ON GO-LINE & PARK MACHINE. MACHINE TO BE CHOCKED OR V DRAINS USED & PARK BRAKE APPLIED. IMPLEMENTS LOWERED WHERE REQUIRED. -TASK COMPLETE- Uncontrolled when printed Page 10 of 10