Safe Work Procedure, Gem Maintenance

Originally Adopted: 9/6/2006 Safe Work Procedure General Maintenance Document No: 00016 Page 1 of 46 Current Adoption:1.
.0 Due For Revision: 9/6/2007 Revoked/Superseded:
Safe Work Procedure General Maintenance
Originally Adopted: 9/6/2006 Safe Work Procedure General Maintenance Document No: 00016 Page 2 of 46 Current Adoption:1.0 Due For Revision: 9/6/2007 Revoked/Superseded:
Purpose
The purpose of this manual is to provide the operator with the correct information to safely carry out general maintenance associated with RC surface drill rigs.
Scope
This SWP covers the : Immobilization General repairs and servicing Jacking and blocking Lifting Welding Battery maintenance Oxy and acetylene cutting Hand tools Tyre changing and inflation associated with surface RC drill rigs
Learning Outcome
At the completion of this training module the operator will be competent to safely carry out general maintenance associated with RC surface drill rigs.
PPE Requirements
Hard Hat, Safety Glasses, Safety Boots, Hearing protection, Gloves
STEP
Immobilisation Procedure
POTENTIAL HAZARD Unexpected movement of vehicle
1. 2. 3. 4. 5.
SAFE WORK PROCEDURE Park machine on hard, level ground where possible. When immobilising a light vehicle or truck, leave the transmission in first gear, engage the park brake and turn engine off. Switch off key and turn off isolation switch. Tag out machine according to tagging regulations as per Swick Drilling Australias Isolation Procedures. Place chocks under wheels where required.
STEP
POTENTIAL HAZARD
General Repairs and Servicing Procedure

Manual handling injuries
SAFE WORK PROCEDURE Always use the Immobilisation Procedure. Because of the size of some of the components, personnel should check the weight of the object. 1. If it is overly heavy or awkward, then assistance from other personnel should be sought. 2. If it is extremely heavy, then some mechanical means should be used. At all times, the correct lifting procedure should be used when removing any components.
Eye injuries Caught in machinery Ring avulsion injuries
1. Always wear protective glasses and boots when working around machines. 2. Do not wear loose fitting or torn clothing. 3. Remove all rings from fingers when working on machines. 4. Where possible, ensure the machine is on a level, hard surface. If jacking is required, follow Jacking and Blocking Procedure.
Slips/falls
1. Use steps and grab handles when mounting or dismounting a machine. 2. Clean any mud, oil or debris from steps, walkways or work platforms before using. 3. Always face the machine when using steps, walkways and ladders.
STEP
POTENTIAL HAZARD
General Repairs and Servicing Procedure Unexpected release of high (cont.)

pressure air Burns/scolds
SAFE WORK PROCEDURE All tools used for repairs or servicing should be of the correct type and in good condition. 1. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. 2. To avoid burns, be alert for hot parts on machines which have been stopped and hot fluids in lines, tubes and compartments. 3. Ensure all protective devices, including guards and shields are properly installed and functioning correctly before starting repair. 4. If a guard or shield is removed before repairs, use extra caution. 5. After service or repair, make sure all protective guards and covers are secured in place on machine. 6. Make sure the machine deck, walkways and steps are free of debris, oil, tools or other items not part of the machine. When servicing machinery, ensure all oil, water and grease levels are correct according to specifications as per the manufacturer
Contact with moving parts
Slips/trips/falls from height
STEP
Jacking and Blocking Procedure
POTENTIAL HAZARD Unexpected hydraulic failure. Crush injury Stand failure/crush injury
1. 2. 3. 4. 5. 6.
Vehicle slipping off jack. Crush injury
SAFE WORK PROCEDURE Do not work on any machine that is supported only by lift jacks or hoists. Immobilize machine according to Immobilization Procedures. Ensure lift jack is of the correct capacity and height for the job. Position the lift jack in an appropriate jacking point and jack machine up to the required height. Install stands in the correct positions and release lift jack slowly until stands take up all weight of the machine. If the top of the stands are not shaped to fit certain machine components, i.e. flat wooden blocks are to be placed between the stand and the machine to prevent slipping.
STEP
POTENTIAL HAZARD
Lifting Procedure
Failure of lifting devices
SAFE WORK PROCEDURE 1. Immobilise the machine according to Immobilisation Procedures. 2. Ensure lifting devices are in good condition and are of the correct capacity for the job. 3. Check slings for fraying and wear. 4. Check chains for stretching, cuts, kinks or any other signs of damage and check that the certification tags are current. 5. Make sure lifting devices are attached correctly to the lift eyes. 6. No side loading on eyes during a lifting operation. 7. Make sure hooks are positioned correctly. 8. When using a forklift for lifting, ensure it is on hard, level ground. 9. Make sure the load to be lifted is within the forklifts capacity. 10. When using slings do not: a) exceed SWL b) drag c) drop from height d) kink e) tie knots in f) join with nut and bolt g) place around sharp corners without packing h) shock load i) induce angles that exceed the SWL j) store in weather k) drag from under load.
STEP
POTENTIAL HAZARD 1. Battery explosion. Burns Flash burns Burns from sparks/slag 4. 5. Inhalation of fumes 6. Fire 7. Explosion of container Electrocution 8. 9. 2. 3.
Welding Procedure
SAFE WORK PROCEDURE If welding on a machine, immobilise according to the Immobilisation Procedure. Disconnect batteries. Ensure all personnel other than the person performing the welding are clear of the area so as to reduce the likelihood of a flash incident. Use the correct welding gauntlets, shield goggles, apron and other protective clothing appropriate to the welding job being performed. Ensure there is adequate ventilation to remove welding fumes from the working area. Check there is no flammable material within ten (10) metres of the welding job. Welding diesel containers should be carried out with the diesel drained and the container filled with water. Avoid welding in and around water wherever possible. If work must be done in wet conditions, ensure rubber boots are used and standing on rubber mats, if appropriate.
STEP
Battery Changing and Charging Procedure
POTENTIAL HAZARD Explosion of battery gas Burns from acid/explosion
SAFE WORK PROCEDURE Batteries give off flammable gases which are explosive. No smoking and no naked flames around batteries. Protective gloves and glasses of the appropriate type should be worn. Immobilise machine according to Immobilisation Procedures. Remove the negative terminal first, then the positive. Remove battery clamps. Remove batteries from machine. This job often requires two people depending on the size and location of the batteries. Where practicable, mechanical lifting devices should be used. Remove the battery and take to a well ventilated area, free of any ignition sources for charging. Remove battery caps and check that the electrolyte is covering the cells. Ensure charger is switched off and connect the charger clamps to battery posts in correct polarity, usually black to negative and red to positive. Check the charger is on the correct voltage for the battery and that it is on low amps, then switch on. If the temperature of the battery exceeds 50 degrees Celsius or it is gassing violently or splashing electrolyte, stop charging or reduce the rate. After the battery is charged, switch off power and disconnect the battery from the charger. Check battery caps to ensure vent holes are clear and then screw back in. Check that the battery is charged.
STEP
POTENTIAL HAZARD
Battery Changing and Charging Procedure. (cont.)
SAFE WORK PROCEDURE Batteries can be connected so that more than one is charged at once. Parallel Charging: Connect the positive of one battery to the positive of another; negative of one to the negative of the other. The number of batteries which may be connected depends on the current capacity of the charger. Only batteries of the same capacity should be charged at once and current will be equally divided amongst the lot. Series Charging: Connect the positive terminal of one battery to the negative of the other. Each battery receives the full current as shown by the charger. The number of batteries which can be connected depends upon the voltage rating of the charging source. Batteries of different capacity can be charged but the rate must be set in line with the lowest capacity battery.
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE
THE USE OF OXYGEN AND ACETYLENE CUTTING EQUIPMENT
Personnel
Personnel who use oxygen and acetylene must: a) Be trained to identify the contents of different gas containers and know their potential hazards from the available MSDS sheets. b) Be trained in the operation and the use of safety and emergency equipment provided (eg. fire extinguishers).
SAFE HANDLING OF OXYGEN AND ACETYLENE BOTTLES
Equipment
Personnel who regularly move or handle gas cylinders, must be provided with: Pinch/crush injuries a) stout gloves (eg. leather) b) protective footwear (eg. steel cap shoes) c) trolley or other suitably designed device for transporting cylinders. There should be provision for securing the cylinder during the moving with a chain. .
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE
THE USE OF OXYGEN AND ACETYLENE CUTTING EQUIPMENT (cont.)

Manual handling injuries
Handling Techniques
Most accidents or injuries whilst handling cylinders of compressed oxygen or acetylene occur whilst moving these cylinders. For this reason, personnel are to: a) remember the mass of the cylinder (up to 100kg) b) to be aware of trapping fingers between cylinders whilst they are being moved c) when it is necessary to lift heavy cylinders, to manually to seek help and observe the lifting posture d) to use a trolley or other suitable device for transporting heavy cylinders, even for a short distance and to ensure that the cylinder is secured e) to ensure regulator withdrawal equipment is disconnected and the valve firmly shut when moving f) to ensure that, when provided, valve protection caps and gas tied outlet cap plugs are securely fitted to cylinders whilst they are being moved and not in use.
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE
THE USE OF OXYGEN AND ACETYLENE CUTTING EQUIPMENT (cont.)

Breakage of valve assy Unexpected release of high pressure gas
Storing Oxygen and Acetylene Cylinders

Cylinders in storage must be: a) stood upright and properly secured to prevent toppling over to protect cylinder valve from damage b) kept with supplied valve protection cap or guard or gas type valve outlet cap/plug securely in place c) segregated in the storage area according to the various categories (eg. flammable - oxygen; non-flammable poison, etc.) d) segregated in the storage area according to content (ie. full or empty) e) manage to ensure that the older stock is used first check periodically for general condition - severe rusting, leaks, etc
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE
SAFE TRANSPORT OF COMPRESSED CYLINDERS OF OXYGEN AND ACETYLENE

Explosion/fire from leaking gas
Checks Prior to Transport

Gas containers must always be checked prior to transport to ensure: a) the valves are closed and not leaking b) the valve outlet sealing plug or cap nut, where supplied, is fitted and tightened using an appropriate tool. This device provides a seal on the valve outlet in the event of the valve being opened by mistake and is particularly important for toxic gases. c) the valve protection cap or guard, where supplied, is correctly fitted. This provides protection for the valve against mechanical damage, eg. if a gas container is dropped, or falls over. d) the cylinder or container is correctly labelled in accordance with the Australian Dangerous Goods Code.
Breakage of valve assy Unexpected release of high pressure gas
Type of Vehicle
Vehicles used for transporting cylinders of pressurised gas must have a well ventilated load area (closed vehicles, eg. private cars, small vans) must never be used to transport toxic gasses and only with added precautions for other gasses. Vehicles carrying gas containers should be equipped with a fire extinguisher suitable for fighting fire or engine fires.
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE
SAFE TRANSPORT OF COMPRESSED CYLINDERS OF OXYGEN AND ACETYLENE (cont.)
Load Security Safety

a) the load on a vehicle must be adequately secured to prevent movement during transport and it is important to bear in mind the mass of the gas containers when securing them to the vehicle b) particular care should be taken when securing small gas cylinders as experience has shown that these can easily be lost. They are best carried in special ventilated cage, but note, they must never be placed in the drivers compartment. c) unattended vehicles carrying gas cylinders should only be parked in proper parking places, preferably those which are secure and away from the general public d) cylinders must not protrude outside vehicles e) liquefied gasses, especially liquefied flammable gas, ie. LPG, must always be transported vertically to ensure the mandatory safety relief device is always in contact with the gas space. This is a legal requirement.
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE
THE
SAFE USE OF COMPRESSED OXYGEN AND Fire/explosion from gas build ACETYLENE up
Gas Usage Area

These should be: a) generally well ventilated b) Cylinders should be arranged so as to minimise fire risk in the vicinity of the gas containers. It may also be necessary to eliminate ignition sources. For example, where flammable gasses are used, when non-combustion applications and where there is a risk of leakage. c) The area must be provided with appropriate safety and emergency equipment and information (eg. fire extinguishers, eye protection, emergency disposal system and the necessary MSDS sheets).
Gas Handling/Control Equipment

It is important to use the correct pressure flow control equipment. The choice of suitable pipework, fittings and equipment is dependent upon the gas operating pressure. The chemical and physical properties of the gas, the gas purity, and other user requirements
Special Consideration
Always use a pressure regulator. Do not pipe at cylinder pressure. Installations handling oxygen must be free of flammable materials (eg. oil and grease).
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE
THE SAFE USE OF COMPRESSED OXYGEN AND ACETYLENE (cont.)
Personnel
Personnel who use compressed gasses such as oxygen and acetylene should be trained in: a) the identification of the gas container contents and the potential hazards. They should also have access to the appropriate material safety data sheets. b) the operation and use of the safety and emergency equipment, where provided (eg. fire extinguishers, eye protection, hand protection, etc.) c) the handling and use of the gas container and its valve d) the correct operation of the gas flow and control equipment e) the importance of ensuring that the gas container is not contaminated f) what emergency procedures to institute should a problem occur
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE
Compressed Gas Cylinder Pre-Use Checks

Prior to connecting equipment and using gas from cylinders: a) check to see if they contain the correct gas for the intended usage by reference to the gas name label, reading the instructions or warnings b) secure properly to prevent toppling over or other movement which would fracture the connecting pipework or damage control equipment c) remove by hand the disposable plastic plug initially fitted to the cylinder valves after filling d) check for cleanliness of the cylinder valve outlet as follows, particularly on subsequent use for fire and matter which may harm equipment and be hazardous: for Class 2.2/5.1 oxidising gasses (eg. oxygen), cracked cylinder valve (open and quickly shut) to remove water and dust. Do not use compressed air or cleaning cloths which may lead to ignition due to oily residues for Class 2.1 flammable (eg. acetylene), use compressed air or a clean brush to remove water or dust. Do not crack the cylinder valve
STEP
POTENTIAL HAZARD Damage to cylinder/valve assy
SAFE WORK PROCEDURE
Care of the Cylinder

a) Do not drop cylinders from a height or allow cylinders to fall over. b) Secure cylinders against falling whilst in use, storage or transport. c) Do not allow naked flames to impinge on cylinders. d) Do not allow any form of heating that would artificially raise the temperature of the cylinder above 45 degrees Celsius. e) Do not use cylinders as rollers or supports for plates. f) Protect cylinders from impact damage from passing vehicles. g) Protect cylinders from paint spray, acids, alkalies, prolonged water contact. h) Do not strike electrical arcs on cylinders. i) Do not cover up or repair signs of damage j) Do not repair cylinder valves. k) Keep cylinders, particularly the valves, clean. Do not use cylinders with dirty valves. Do not attempt to clean valves l) Close cylinder valves when the cylinder is not in use. Also when the cylinder is empty. Refit any supplied valve cap or gas tied outlet cap or plug.
Explosion/fire
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE

Burns Explosions
EMERGENCY PROCEDURES WHEN DEALING WITH FIRE SITUATIONS OR FLAMMABLE COMPRESSED GASSES
In general: a) if possible, immediately isolate the gas supply so that it does not continue to flow into the affected area b) Fire threatening compressed gas cylinders. If there is a risk of rupture, explosion of cylinders subjected to prolonged heating (such as in a fire), such cylinders should be moved to a protected place before they become too hot, or if this is not possible, cooled with water hosed from a protected position, a safe distance away. c) Any cylinder that has been involved in a fire, must be clearly marked as such the supplier must be notified accordingly to prevent hazards to people who refill cylinders. Never cover up a fire damaged cylinder. d) Ignited flammable gas leak: If possible, isolate the gas supply. If this is not possible, DO NOT extinguish the flame. Try to ensure the flammable gas burns in as controlled a manner as possible. It does not ignite anything else and it does not impinge upon any pressurised gas containers, equipment or pipelines. If possible, keep surrounding area equipment cooled by spraying with water from a protected and safe distance.
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE
CARE AND USE OF HAND TOOLS
Common Sense Rules When Using Hand Tools

1. Select the right tool for the job 2. Use it in the correct manner 3. Make sure it is in good condition 4. Store it safely Remember hand tools will not abuse you unless you abuse them. Hammers Hammer Face It is important that the hammer face is keep clean and free of grease as these cause the hammer to slip possibly resulting in an injury. Never hit any items such as files that are harder than the hammer as this produces pitting of the face which in turn can cause slippage or twisting of the hammer during use. Check the face of the hammer for these defects and get them cleaned or refaced. Safety Checks on Hammers 1. Before using a hammer, check that it is safe to use. 2. Check that the hammer head is firmly attached to the handle. 3. Check that the holding wedges are tight. Never use nails as holding wedges. 4. Check that the hammer handle is free from cracks, splits and splinters. 5. Check that the face is free from oil and grease or other substances and free of pit marks.
Material flying off hammer face Puncture injury
Loose hammerhead projectile
STEP
POTENTIAL HAZARD
CARE AND USE OF HAND TOOLS (cont.)
SAFE WORK PROCEDURE If any of the above items are found to be faulty, do not use the hammer, but replace it as soon as possible. Use of Hammers There are a few safety rules associated with the use of a hammer. 1. Keep hands and fingers clear of the object being struck if possible. 2. Place the hand at the base of the handle, ie do not choke the hammer. The free end can strike objects and put your swing off. 3. When chipping at metal using chisels, wear safety glasses - eyes cannot be replaced. 4. Do not use the side of the hammer head to strike objects. Use only those faces designed for striking. 5. Do not use hammers that are faulty or damaged in any way.
Foreign body in eyes
Spanners
Spanners vary considerably in shape and size to provide ease of operation and provide ease of operation under different conditions. There are four basic types: 1. open end spanner incorporating shifting spanner 2. tube or box spanners 3. socket spanners 4. ring spanners
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE The choice of spanner for use on any particular job is one that: 1. fits exactly 2. allows room for use 3. allows the job to be done in the shortest possible time Safe Use of Spanners 1. Exert effort on open end or ring spanners by pulling. Pulling is the safest as there is less chance of hitting knuckles if the spanner or nut gives suddenly. 2. Use both hands on big spanners. 3. Keep yourself balanced and brace to avoid slipping in the event that the spanner or nut giving suddenly. 4. Hold onto some support if there is any chance of falling. 5. Use two hands when turning tubular box spanners. Normal spanners have a length that is approximately ten times the width of the jaw opening. The correct pull on the end of the shank will produce the required turning effect on the nut. Never exert excessive pull on a spanner, particularly by using a pipe to extend the length of the spanner. Excess turning effect could: 1. 2. 3. 4. strip the thread shear the bolt strain the jaws of the spanner make the spanner slip and cause an accident
Contact with injuries
Slips/falls
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE
Importance of Correct Fit

It is important not to use a spanner that does not fit correctly. It could result in injury to you and damage to the spanner and the nut. To fit exactly, a spanner must be the correct size, placed correctly on the nut and in good condition. Never use a spanner from one thread system on another thread system. Spanners have there jaws slightly wider than the width of the nut so they can be placed into position with ease. However, any more than 1/500th of a millimetre clearance causes the spanner to slip under pressure. Place the spanner so that the jaws bear fully on the flats of the nut. Failure to thrust the spanner fully on the nut is liable to damage the spanner and the nut. Only when the lower jaw makes contact with the outer edge of the flat, is a maximum turning effect on the nut produced. In the correct position shown, the spanner should pivot about the tip of the lower jaw, springing open the jaws and bearing the edge of the flat. This could possibly result in injury to the user.
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE
Adjustable Spanners
Most common types of adjustable spanners are similar to open end spanners but they have one moveable jaw. The opening between the jaw of a typical 250mm spanner can be adjusted from 0 to 28mm. Adjustable spanners are convenient for use where a full kit of spanners cannot be carried as for example, on maintenance work. They are not intended to replace fixed spanners which are more suitable for heavy work. Keep adjustable spanners clean and oil moving parts occasionally. Inspect for damage before use. If the moveable jaw or knurled screw are cracked or worn, replace them with spare parts. When using adjustable spanners, it must be remembered that the length of the handle was designed to suit the maximum jaw opening. Therefore, with smaller nuts, a smaller effort should be applied to the handle, otherwise shearing of the bolt can result.When using adjustable spanners, it must be remembered that the length of the handle was designed to suit the maximum jaw opening. Therefore, with smaller nuts, a smaller effort should be applied to the handle, otherwise shearing of the bolt can result.
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE
The Stillson
These wrenches are used primarily for turning pipes with a wide range of diameters. Fixed to the handle is a jaw with outward facing teeth. Attached to this handle by a pivot pin is a spring loaded casing that carries a knurled adjusting nut. This engages with a thread on the adjustable arm of the jaw with inward facing teeth. Once the jaws are adjusted, the spring loading keeps them in contact with the work and the toggle action causes the hardened teeth to bite into the work. Use two hands to set it on the work. Centre the work against the fixed jaw. Use the left thumb to push the adjusting nut around to close the jaws. When the grip is tight, pull the handle with the right hand. When changing grip, use the left hand to keep the adjusting nut steady and thereby the jaws are in the correct position. The jaws will mark the surface of the work, therefore never use Stilton wrenches on polished or plated work. Never grip hardened materials as this will damage the teeth. Stillson wrenches should never be used on nuts or bolt heads unless that nut is so damaged, it has to be discarded.
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE Allen Keys These are hexagonal section bars of tool steel bent into an L shape. They used to turn set screws having internal hexagonal sockets and are available in sets ranging in size from 1.5mm to 25mm. When using these socket wrenches, make sure socket and wrench are clean before use. Use the correct size and insert to the full depth. Discard those wrenches with worn and rounded edges as these are liable to slip
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE Screw Drivers Screw drivers are designed to tighten or loosen screws and should not be used for any other purpose. Hand-held screw drivers include standard types with tips to suit screw slots. Special types (Philips) with tips to recessed head screws. Standard Screw Drivers
Standard screw drivers are made with tips to turn screws with slotted heads, blades of hardened and tempered carbon steel. Usually handles are made of metal, wood or moulded insulated material, shaped to give a good grip for turning.
Standard Shaped Tips A correctly shaped standard tip on a screw driver should ensure that it engages the screw slot efficiently, is almost as thick as the slot, exerts its turning moment at the bottom of the slot, has a width not less than three quarters the length of the slot, and it turns the screw with a minimum of downward pressure. If the incorrect screw driver is used, this may result in damage to the screw driver, damage to the workplace or injury to the hands. Prior to use, screw drivers should be inspected and if the blade is not of a uniform taper, then it should be removed and replaced.
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE Selecting The Correct Sized Tip It is most important when using a screw driver that the correct size of the tip is selected. The width of the tip should be almost equal to the length of the bottom of the slot. Too wide a tip and damage the workplace whereas too narrow a tip can damage the head of the screw. Tips that are too narrow exert turning force too close to the screw axis. Under these circumstances, the turning pressure tends to damage the screw driver tip or the screw head rather than turn the screw. The thickness of the tip should almost equal the width of the slot. If, on the other hand, the tip is too thick, the tip cannot be inserted into the slot without causing damage to the screw head. Find out the range of screw drivers that best suit your work and always use the correct one.
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE Using a Screw Driver After deciding which size tip is required for any particular job, select the longest suitable screw driver with that size tip. Ensure that the handle of the screw driver and your hands are dry and free of grease and oils. Hold the screw driver with its axis in line with the axis of the screw. Guide the blade with the left hand. Apply just sufficient pressure with the right hand to keep the tip in the slot and twist firmly and steadily. Always brace small work against the bench or other firm support before using a screw driver. Never hold small work in your left while using a screw driver as it could slip and pierce your hand. To turn large screw, use a screw driver with a square blade using a close fitting spanner on the blade to give extra turning force. Never use pliers to apply twisting force to square blade of this type of screw driver. Impact screw drivers are also available for this class of work.
Pierce injuries
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE Special Type of Screw Drivers for Recessed Head Screws A wide variety of recessed head screws are used in manufactured articles. It is important that the correct form of screw driver is used on these screws as in the case of Philips Head screws. Remember - right tool, right job. Using a Screw Driver After deciding which size tip is required for any particular job, select the longest suitable screw driver with that size tip. Ensure that the handle of the screw driver and your hands are dry and free of grease and oils. Hold the screw driver with its axis in line with the axis of the screw. Guide the blade with the left hand. Apply just sufficient pressure with the right hand to keep the tip in the slot and twist firmly and steadily. Always brace small work against the bench or other firm support before using a screw driver. Never hold small work in your left while using a screw driver as it could slip and pierce your hand. To turn large screw, use a screw driver with a square blade using a close fitting spanner on the blade to give extra turning force. Never use pliers to apply twisting force to square blade of this type of screw driver. Impact screw drivers are also available for this class of work.
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE Special Type of Screw Drivers for Recessed Head Screws A wide variety of recessed head screws are used in manufactured articles. It is important that the correct form of screw driver is used on these screws as in the case of Philips Head screws. Remember - right tool, right job.
STEP
POTENTIAL HAZARD Pliers
SAFE WORK PROCEDURE Pliers, tongs and cutters are from the one family of tools. They have a pair of legs, joined by a pivot, each leg consists of a long handle and a short jaw and thus applies the principles of levers to gain mechanical advantage. Small pressure on the handles gives great pressure on the jaws. Some of the more popular types of pliers used are: 1. multi-grip pliers 2. engineers or combination pliers 3. side cutters Multi-Grip Pliers Multi-grip pliers are slip joint pliers having a sharp pivot which can fit into a number of openings in the legs. This gives a range of jaw openings allowing parallel gripping by the jaws in a number of position. The longer handles on multi-grip pliers allow a very strong jaw grip to be obtained. However, care must be taken not to exert too much pressure as this could damage the shaped pivot pin.
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE
Engineers or Combination Pliers

A standard engineers or combination pliers as they are called should have: 1. 2. 3. 4. 5. a serrated flat jaw grip for general gripping a serrated pipe grip jaw for gripping cylindrical objects side cutting blades for cutting small diameter soft wires shear cutters for cutting steel wire bear or insulated handles.
When using combination pliers for cutting short ends from wire, the same precautions as described in the use of side cutters, should be observed. Side Cutters
These should have: 1. jaws set at an angle 2. a single cutting blade jaw Side cutting pliers are used for cutting small diameter wires, cutting wires close to flush surfaces. Care should be exercised when cutting short ends of wire, especially steel wire, as they are liable to fly when cut. Cut with the free end pointing away from you and wear safety spectacles if necessary
Foreign body in eyes
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE Using Pliers Safely There are some basic safety rules to be observed when using pliers. Not only will the observance of these rules help to prevent the user from receiving injury, but will also extend the life of the tool. 1. always use the correct size and type of pliers 2. do not try to cut material that is too large or too hard for the cutting jaws as this could deform or break them 3. never try to put extensions on the handles as this could break them 4. never use pliers to turn nuts - use the correct size spanner 5. when gripping an object, pull towards you to turn it. There is less danger of slipping 6. never use unprotected pliers to grip a hardened, polished or plated surface. 7. keep the pliers clean. Wash in a suitable solvent and dry regularly 8. oil the pivot pin to keep it free moving and reduce wear 9. inspect the pliers regularly. Worn tools can slip and damage your hand and the work piece. 10. replace damaged insulating covers on the handles of electricians pliers. 11. never subject pliers to heat as this can ruin them 12. worn out pliers can be used as tongs for holding hot work when they are useless for anything else. Always wear gloves for this operation.
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE Hacksaws Most hand hacksaws have frames that are adjustable to take several different lengths of blade. Set screw enables the bow to be set in different positions and the handle to facilitate this. The tension in the blade holding pieces has square shanks to allow them to be set in any one of four positions, from the flats of these pieces hardened steel pins projected at a slight angle to hold the blade. A wing nut it provided to apply the correct tension to the blade. Hacksaw frames should be well balanced and rigid when tension. When not in use, it is most important that the tension should be removed from the frame by loosening the blade. Clean and oil the tension piece and wing nut from time to time. To make cuts greater than the depth of the bow, it is necessary to set the blade at right angles to the plane of the frame. This can only be achieved if the work piece is sufficiently narrow to clear the frame. Choice of Hacksaw Blades When performing any work where a hacksaw is to be used, the selection of the blade is of the utmost importance. The following notes may help you in deciding which hacksaw blade is required for the particular job in hand. Hacksaw blades are identified by the pitch of the teeth and the number of teeth per inch (tpi). The size of the teeth is directly related to the pitch - the finer the pitch, the smaller the teeth.
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE Avoiding Damage to the Blade Obeying some simple common sense rules will help extend the life of your hacksaw blade. 1. never allow the teeth to strike a sharp edge or straddle thick work as this causes complete teeth to be broken out 2. limit the downward pressure on the blade when there are only a small number of teeth in contact with the work. Excessive pressure will crack the blade or break the points of the teeth 3. keep the correct tension on the blade 4. keep the frame upright so that the blade does not tilt in the cut 5. keep cutting straight so that the sideways thrust does not twist the blade 6. normally, blades are pulled through the work by the front of the frame, but if they jam in the cut, thrust from the back of the frame causes the blade to buckle and break 7. always inspect the blade before starting a cut 8. replace blades that are worn, cracked or have missing teeth
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE
CHANGING TYRES
Unexpected movement of the vehicle Interaction with other vehicles
Procedure for changing a tyre

Ensure the truck is parked on a level flat hard surface. Ensure ignition is off. If on the road, ensure hazard lights are switched on and safety triangles (if available) are placed in the appropriate position. Ensure a wheel, other than the one being jacked, is chocked on both sides. Safety glasses and steel toe shoes are worn. Locate jack. Remove spare wheel from carrier and place beside flat tyre. If there are no jack points, place jack under axle as close to the tyre as possible. Jack the vehicle until jack takes the weight of the vehicle. Make sure the jack is capable of lifting and holding the weight. Check for left or right hand thread markings Loosen wheel nuts without fully removing. Jack vehicle until wheel is free. . Safely release pressure from wedge (if fitted) by tapping with wheel brace. Loosen nuts, studs and wedges with wheel brace and remove.
Remove outer wheel

Place wheel brace under bottom of tyre to take the weight off. Remove tyre wheel and or rim from vehicle taking care not to damage stud threads. Remove tyre and lean it against the truck. Remove spacer and place beside wheel.
Remove inner wheel

Place wheel brace handle under bottom of tyre to take the weight off. Use short sharp upward movement with wheel brace. Pull wheel with other hand and slide rim off hub.
Replace inner wheel

Make sure all surfaces on hub wheel spacers are clean and without damage. Clean and prepare hub or spider for remounting of tyre wheel rim assembly. Place rim in position lined up with spider, hub or retaining studs. Ensure the valve faces outwards. Carefully mount wheel rim assembly making sure not to damage stud threads. Make sure that the valve stem is correctly positioned and accessible. Use wheel brace handle to lift tyre, then push wheel into position. Make sure valve is positioned between the two studs. Inspect and refit spacer if applicable.
Replace outer wheel

Ensure valves are placed for easy access. Spider and rim assemblies will require correct positioning of lugs and pre-tensioning of nuts so that the rotating assembly can be checked for lateral runout. When this is achieved and the vehicle is lowered from the jack, proceed with correct nut tensioning in the right
sequence. Replace individual wedges retaining studs and nuts. Wheel and hub assemblies will be self-centering provided that the nuts have been tightened in the correct sequence and in the correct torque. Note - make sure that nut and hole contours are correctly matched. Tighten nuts in sequence. Lower and remove jack. Securely tighten wheel nuts in sequence and correct torque - spider rim to 250 and stud wheel hub to 450 to 500. Replace flat tyre in carrier and resecure. Replace tools and jack. Remove chocks, warning sign and turn off hazard lights. Recheck wheel nuts after driving for approximately 50 kilometres.
Correct jacking procedure

use jack of sufficient capacity and in good condition use a base plate and or timber block under the jack to ensure: weight is spread over a larger area reduce the amount ram required before contact is made with jacking point ensure jack is set up as close to vertical as possible and head of jack is positioned in the centre of the jacking point to prevent jack falling over or toppling as the load is applied ensure jack release screw is in the raise position ensure handle is clear of obstructions pump jack until wheel is clear of ground Avoid being under vehicle while on the jack unless stand or wheel is in place
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE
WHEEL NUT TIGHTENING SEQUENCE
STEP
POTENTIAL HAZARD
SAFE WORK PROCEDURE
TYRE INFLATION PROCEDURE
Immobilize the machine according to Immobilization Procedure. Remove valve core and make sure tyre is completely deflated. Always use correct tools and equipment. Remove locking rings and flanges and tyre using correct tools and equipment. 5. Examine all flanges, locking rings and rim gutters. 6. Make sure that all components are clean and adequately lubricated. 7. Carefully assemble tyre wheel components. 8. Once a wheel rim and tyre have been assembled and before any inflation, check the position of loose flanges, sleeve and locking rings for correct seating. 9. Some method of restraining the locking ring must be in place prior to the tyre being inflated and it must be ensured that the tyre is properly centred on the rim and that the flange, locking ring and bead are correctly seated. 10. All inflation lines must have a sufficient length of hose so as personnel can stand clear during the inflation process. 11. In conjunction with this inflation device must be a valve and gauge so the person operating the inflation device knows what pressure the tyre is being inflated to. 12. Final inflation of the assembly must be an approved restraining device, ie. a) Cage. This can be used for small tyres and when available; b) with specially designed chains if available; c) by placing the light vehicle against the rim of the tyre that is to be inflated. Before releasing the device, the tyre must be visually checked to see that the rim is correctly seated. Only trained personnel are to carry out this procedure. 1. 2. 3. 4.

Safe Work Procedure, Gem Maintenance

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Safe Work Procedure, Gem Maintenance

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Originally Adopted: 9/6/2006 Safe Work Procedure General Maintenance Document No: 00016 Page 1 of 46 Current Adoption:1.

.0 Due For Revision: 9/6/2007 Revoked/Superseded:

Safe Work Procedure General Maintenance

POTENTIAL HAZARD Unexpected movement of vehicle

General Repairs and Servicing Procedure

Eye injuries Caught in machinery Ring avulsion injuries

General Repairs and Servicing Procedure Unexpected release of high (cont.)

Contact with moving parts

Slips/trips/falls from height

Jacking and Blocking Procedure

Vehicle slipping off jack. Crush injury

Battery Changing and Charging Procedure

POTENTIAL HAZARD Explosion of battery gas Burns from acid/explosion

Battery Changing and Charging Procedure. (cont.)

SAFE WORK PROCEDURE

THE USE OF OXYGEN AND ACETYLENE CUTTING EQUIPMENT

SAFE HANDLING OF OXYGEN AND ACETYLENE BOTTLES

SAFE WORK PROCEDURE

THE USE OF OXYGEN AND ACETYLENE CUTTING EQUIPMENT (cont.)

SAFE WORK PROCEDURE

THE USE OF OXYGEN AND ACETYLENE CUTTING EQUIPMENT (cont.)

Storing Oxygen and Acetylene Cylinders

SAFE WORK PROCEDURE

SAFE TRANSPORT OF COMPRESSED CYLINDERS OF OXYGEN AND ACETYLENE

Checks Prior to Transport

Breakage of valve assy Unexpected release of high pressure gas

SAFE WORK PROCEDURE

SAFE TRANSPORT OF COMPRESSED CYLINDERS OF OXYGEN AND ACETYLENE (cont.)

Load Security Safety

SAFE WORK PROCEDURE

Gas Usage Area

Gas Handling/Control Equipment

SAFE WORK PROCEDURE

THE SAFE USE OF COMPRESSED OXYGEN AND ACETYLENE (cont.)

SAFE WORK PROCEDURE

THE SAFE USE OF COMPRESSED OXYGEN AND ACETYLENE (cont.)

Compressed Gas Cylinder Pre-Use Checks

POTENTIAL HAZARD Damage to cylinder/valve assy

SAFE WORK PROCEDURE

THE SAFE USE OF COMPRESSED OXYGEN AND ACETYLENE (cont.)

Care of the Cylinder

SAFE WORK PROCEDURE

THE SAFE USE OF COMPRESSED OXYGEN AND ACETYLENE (cont.)

SAFE WORK PROCEDURE

CARE AND USE OF HAND TOOLS

Common Sense Rules When Using Hand Tools

Material flying off hammer face Puncture injury

Loose hammerhead projectile

CARE AND USE OF HAND TOOLS (cont.)

Foreign body in eyes

CARE AND USE OF HAND TOOLS (cont.)

Contact with injuries

SAFE WORK PROCEDURE

CARE AND USE OF HAND TOOLS (cont.)

Importance of Correct Fit

SAFE WORK PROCEDURE

CARE AND USE OF HAND TOOLS (cont.)

SAFE WORK PROCEDURE

CARE AND USE OF HAND TOOLS (cont.)

CARE AND USE OF HAND TOOLS (cont.)

CARE AND USE OF HAND TOOLS (cont.)

CARE AND USE OF HAND TOOLS (cont.)