Operational Induction

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Jeffry Whitehead
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1 Operational Induction

2 Operational Induction Contents Competence Operator Responsibilities High Risk Activities Isolating and Tagging What is Competence? Competencies and Licences Verification of Competency Pre-start checks and fault reporting Safe operation procedures) Vehicle recovery and Jump starting Working at Heights Entering and working in confined spaces Line of Fire Loading, Lifting and Slinging Isolating Energy Sources Isolation Points and Tags Personal Locks Three Steps of Isolation

3 1. COMPETENCE What is Competence? Competence = demonstrated ability It means being able to show that you are able to do something (i.e. operate a Forklift) It requires objective assessment based on: Direct / observed evidence Indirect evidence Supporting evidence

4 1. COMPETENCE Why is Competence Important? No one is to move operate maintain or modify any piece of plant or equipment unless they have been deemed competent to do so

5 1. COMPETENCE Competencies and Licences

1. COMPETENCE Verification of Competence (VOC)

to operating plant Move & Test only VOCs used for

6 1. COMPETENCE Verification of Competence (VOC) Demonstrate current competence Complement licences/quals/tickets Are specific to machine make/model Are conducted by Trainers on site prior to operating plant Move & Test only VOCs used for Maintenance personnel Plant Operator Assessment VOC MSC-TRD-VOC-002

1. COMPETENCE Knowledge Check: 1. Competence 1. When can you operate machinery/vehicles without demonstrating competence? Never! Must be deemed competent prior to operating any plant.

7 1. COMPETENCE Knowledge Check: 1. Competence 1. When can you operate machinery/vehicles without demonstrating competence? Never! Must be deemed competent prior to operating any plant. If in doubt: 2. What form is used to demonstrate current competence? Verification of Competency (VOC) 3. What would you need in order to operate a Forklift? WorkSafe High Risk Licence AND a VOC

8 2. OPERATOR RESPONSIBILITIES 2. Operator Responsibilities Pre-start checklists Fault reporting Safe operation procedures Vehicle recovery and Jump starting

Large Mobile Plant and Equipment i.e., Loaders, Haul Tucks, Bobcats 4.

9 2. OPERATOR RESPONSIBILITIES 4 Types of Pre-start Forms 1. Light Vehicle (including trailers) 2. Small tools and Equipment i.e., quick cut, welders 3. Large Mobile Plant and Equipment i.e., Loaders, Haul Tucks, Bobcats 4. Crusher Circuit Equipment i.e., Crushers, Screeners, Reclaimers 5. Heavy Vehicle Accredited Vehicles 6. Forklift Pre-Start Procedure MSC-PLA-PRO-001

10 2. OPERATOR RESPONSIBILITIES 4 Types of Pre-start Forms 1. Light Vehicle (including trailers) 2. Small tools and Equipment i.e., quick cut, welders 3. Large Mobile Plant and Equipment i.e., Loaders, Haul Tucks, Bobcats 4. Crusher Circuit Equipment i.e., Crushers, Screeners, Reclaimers 5. Heavy Vehicle Accredited Vehicles 6. Forklift Pre-Start Procedure MSC-PLA-PRO-001

Crusher Circuit Equipment i.e., Crushers, Screeners, Reclaimers 5.

11 2. OPERATOR RESPONSIBILITIES 4 Types of Pre-start Forms 1. Light Vehicle (including trailers) 2. Small tools and Equipment i.e., quick cut, welders 3. Large Mobile Plant and Equipment i.e., Loaders, Haul Tucks, Bobcats 4. Crusher Circuit Equipment i.e., Crushers, Screeners, Reclaimers 5. Heavy Vehicle Accredited Vehicles 6. Forklift

12 2. OPERATOR RESPONSIBILITIES 4 Types of Pre-start Forms 1. Light Vehicle (including trailers) 2. Small tools and Equipment i.e., quick cut, welders 3. Large Mobile Plant and Equipment i.e., Loaders, Haul Tucks, Bobcats 4. Crusher Circuit Equipment i.e., Crushers, Screeners, Reclaimers 5. Heavy Vehicle Accredited Vehicles 6. Forklift

2. OPERATOR RESPONSIBILITIES Additional HVA Form 1.

13 2. OPERATOR RESPONSIBILITIES Additional HVA Form 1. Light Vehicle (including trailers) 2. Small tools and Equipment i.e., quick cut, welders 3. Large Mobile Plant and Equipment i.e., Loaders, Haul Tucks, Bobcats 4. Crusher Circuit Equipment i.e., Crushers, Screeners, Reclaimers + Heavy Vehicle Accredited Vehicles 1. Forklift

2. OPERATOR RESPONSIBILITIES Daily Pre-start checks Important notes: 1. Pre-starts must be completed if it is the first use of the day 2. Ensure correct form is completed correctly 3.

14 2. OPERATOR RESPONSIBILITIES Daily Pre-start checks Important notes: 1. Pre-starts must be completed if it is the first use of the day 2. Ensure correct form is completed correctly 3. Categorise the defects & resulting action 4. Ensure all relevant parties authorise operation 5. Pre-starts are forwarded onto the Plant Department for review Pre-Start Procedure MSC-PLA-PRO-001

15 2. OPERATOR RESPONSIBILITIES Pre-start checks a closer look The types of checks conducted during a pre-start of the external areas of an LV include (but not limited to): What do you check for Tyres and Rims? What happens if you find an issue? Pre-Start Procedure MSC-PLA-PRO-001

16 2. OPERATOR RESPONSIBILITIES Defect Categories There are three (3) categories of defect : No defect found Action Required Not Applicable Category A Category B Category C Must not be operated until faults rectified Faults to be rectified, unless authorised by Supervisor or Fitter May be operated, Supervisor to be notified Defining features: Anything affecting the handling, stopping or safety of the vehicle Defects which require review to determine if safe to operate Peripheral defects not directly affecting operation Examples: Steering, brakes, lights, seat belts Door locks, fluid leaks, abnormal starting noises Cosmetic issues, accessories, air con Plant Breakdown & Defect Rectification Procedure MSC-PLA-PRO-006

2. OPERATOR RESPONSIBILITIES Fault Reporting Category A faults must be immediately communicated to Site Supervisor Always give as much detail as

17 2. OPERATOR RESPONSIBILITIES Fault Reporting Category A faults must be immediately communicated to Site Supervisor Always give as much detail as possible when a fault is identified Site Supervisors then review and submit to CFC Plant Plant Breakdown & Defect Rectification Procedure MSC-PLA-PRO-006

2. OPERATOR RESPONSIBILITIES Safe Operating Procedures You have the right to if you feel unsafe 1. All operators must demonstrate competence 2.

18 2. OPERATOR RESPONSIBILITIES Safe Operating Procedures You have the right to if you feel unsafe 1. All operators must demonstrate competence 2. All vehicles are fitted with tools to deal with emergency situations 3. Speed limits must always be observed 4. Breakdowns: Maintain communication and stay with the vehicle 5. Proper housekeeping at all times Vehicle Operation and Recovery MSC-OPS-WP-02-09

2. OPERATOR RESPONSIBILITIES Light Vehicles All WA road or specific driving rules Establish positive communications must be followed prior to entering ay work area or Seat belts are to be worn at all

19 2. OPERATOR RESPONSIBILITIES Light Vehicles All WA road or specific driving rules Establish positive communications must be followed prior to entering ay work area or Seat belts are to be worn at all approaching operating plant times Extended journeys: Operators are responsible for all Drivers to have a break every 20 passengers mins Mobile phones: Require Journey Management Only used by Site Supervisors Plans (JMP) Hands-free kits are only for voice Operators must have a zero alcohol calls (no texting) limit at all times Vehicles are reverse parked No parking company vehicles Windows up policy is observed outside licenced premises No passenger is allowed to carry or Loads must be secured for travel consume alcohol Light Vehicle Operations MSC-OPS-WP-02-17

2. OPERATOR RESPONSIBILITIES Vehicle Operation and Recovery MSC-OPS-WP-02-09 Off-Road Vehicle Recovery Single Vehicle (First recovery attempt): DO: Use the correct PPE for the task.

20 2. OPERATOR RESPONSIBILITIES Vehicle Operation and Recovery MSC-OPS-WP Off-Road Vehicle Recovery Single Vehicle (First recovery attempt): DO: Use the correct PPE for the task. Use approved tow chains only. Maintain horn signals and radio communications. Dig sand/mud from beneath vehicle/around tyres Use planks or solid objects to set up ramps to drive out on DO NOT: Push or pull with Buckets. Not use lifting or binder chains. Use chains without gloves. Make bucket to Bucket contact with the machines. Try to avoid wheel spin

2. OPERATOR RESPONSIBILITIES Vehicle Operation and Recovery MSC-OPS-WP-02-09 Off-Road Vehicle Recovery Assisted Recovery (Final Recovery option): DO: Towing is preferred to snatching Secure Tow using

21 2. OPERATOR RESPONSIBILITIES Vehicle Operation and Recovery MSC-OPS-WP Off-Road Vehicle Recovery Assisted Recovery (Final Recovery option): DO: Towing is preferred to snatching Secure Tow using designated towing or recovery points and a Tow Line or tested snatch strap rated at least twice the weight of the vehicle Towing vehicle should be in reverse (strongest gear) DO NOT: Never used worn/damaged towing or recovery points Spectators should not approach closer than 1.5 length of strap away from either attachment point

2. OPERATOR RESPONSIBILITIES Jump Starting 12V Vehicles You have the right to 1.

Connect jump leads as follows: Positive (A) to Positive (B) Negative (C) to Negative (D)* 6.

22 2. OPERATOR RESPONSIBILITIES Jump Starting 12V Vehicles You have the right to 1. Notify your Supervisor of Jump Start requirement 2. Complete a 5 step risk assessment 3. Set up work area and control areas 4. Apply park brakes and transmissions of support and dead vehicle are in neutral 5. Connect jump leads as follows: Positive (A) to Positive (B) Negative (C) to Negative (D)* 6. Start Vehicle 7. Disconnect Positive THEN Negative Leads 8. Return jumper leads to storage area if you feel unsafe Support Car Dead Car Jump Starting Work Practice MSC-OPS-WP-02-26

23 2. OPERATOR RESPONSIBILITIES Knowledge Check: 2. Operator Responsibilities 1. When should you complete a pre-start form? Prior to operating any machine when it is the first use of the day 2. What category of defect would anything affecting the handling, stopping or safety of the vehicle? such as spongey brakes? Category A Must not operate until faults rectified 3. What must you establish prior to entering an active work area or approaching operating plant? Positive communications and permission to enter/approach 4. What is the final recovery option available? Assisted (i.e. Towing with an aid vehicle). 5. Which jump leads are connected FIRST? Positive to Positives THEN Negative to Negative.

24 3. HIGH RISK ACTIVITIES High Risk Activities Line of Fire Confined Spaces Working at Heights Lifting and load restraint

it s the path of which an object/energy will travel Common Examples: Kick back from electric hand tools Torque wrenches / levers used to

25 3. HIGH RISK ACTIVITIES What is Line of Fire? Line of Fire You are in the line of fire if you position yourself such that you will be injured if the energy is released or misdirected it s the path of which an object/energy will travel Common Examples: Kick back from electric hand tools Torque wrenches / levers used to apply force Chains or slings under tension Loads that could fall or tip as restraints are released Fluids (hydraulic, air, water) when a tap is opened or a fitting loosened Shards flying when hitting brittle materials with a hammer

eliminate these hazards entirely is possible, but if not, we

26 3. HIGH RISK ACTIVITIES Line of Fire: Directing a Loader Operator At Risk: Positive: The first priority should be to eliminate these hazards entirely is possible, but if not, we want people to focus on moving themselves out of the line of fire

be to eliminate these hazards entirely is possible, but if not,

27 3. HIGH RISK ACTIVITIES Line of Fire: Using a Hand Tool to Adjust Equipment At Risk: Positive: The first priority should be to eliminate these hazards entirely is possible, but if not, we want people to focus on moving themselves out of the line of fire

28 3. HIGH RISK ACTIVITIES Line of Fire: Other at Risk Activities Towing

29 3. HIGH RISK ACTIVITIES Line of Fire: Other at Risk Activities Suspended Loads

30 3. HIGH RISK ACTIVITIES Line of Fire: Other at Risk Activities Polywelding

31 3. HIGH RISK ACTIVITIES Line of Fire: Other at Risk Activities Pressurised Equipment

32 3. HIGH RISK ACTIVITIES Line of Fire: Other at Risk Activities Reversing Plant

3. HIGH RISK ACTIVITIES Confined Spaces Work Practice definition: An enclosed or partially enclosed space not designed as a workplace with restricted means for entry and exit.

33 3. HIGH RISK ACTIVITIES Confined Spaces Work Practice definition: An enclosed or partially enclosed space not designed as a workplace with restricted means for entry and exit. It may have / have the potential for an unsafe oxygen or air contaminant level Simply put, it s any confined area not designed for working in where there is the potential for compromised air: Storage tanks, boilers, pressure vessels, silos Manholes Communication Pits Pipes, sewers, shafts or ducts Trenches Large Engine Bays Confined Space Entry MSC-OPS-WP-01-08

3. HIGH RISK ACTIVITIES Confined Spaces Confined Space Entry MSC-OPS-WP-01-08 If you are required to enter

years) Gas Testing Atmospheres Training (as required) Entry Attendant (Stand-by Person) Reviewed the

34 3. HIGH RISK ACTIVITIES Confined Spaces Confined Space Entry MSC-OPS-WP If you are required to enter and work in confined spaces, you must have: Enter and Work in Confined Spaces Training (current within two years) Gas Testing Atmospheres Training (as required) Entry Attendant (Stand-by Person) Reviewed the job-specific approved JHA and emergency rescue plan and completed the Confined Space Checklist Confined Space Permit

3. HIGH RISK ACTIVITIES Working at Heights Work Practice definition: access or egress to/from, ascending, descending or working in any position where a person can or has the potential to fall from

35 3. HIGH RISK ACTIVITIES Working at Heights Work Practice definition: access or egress to/from, ascending, descending or working in any position where a person can or has the potential to fall from one level to another and injure him or herself. This includes the potential to fall through openings or into excavations. Simply put, it s where there is the potential to fall and cause harm: Working with 2m of an open edge Working in a man cage/ewp Erecting/dismantling scaffolding Removing a hand rail Work areas with the potential for collapse BARRICADING AND SIGNAGE MUST BE ERECTED AT EXPOSED EDGES WARNING OF FALL POTENTIAL Working at Heights MSC-OPS-WP-01-07

3. HIGH RISK ACTIVITIES Working at Heights Working at Heights MSC-OPS-WP-01-07 If you are required to work at heights, you must have: Working at Heights Training (current

36 3. HIGH RISK ACTIVITIES Working at Heights Working at Heights MSC-OPS-WP If you are required to work at heights, you must have: Working at Heights Training (current within two years) Reviewed the job-specific approved JHA and emergency rescue plan A WorkSafe High Risk Licence (as applicable, e.g., EWP) Inspected/serviceable Fall Arrest Equipment

3. HIGH RISK ACTIVITIES Working at Heights MSC-OPS-WP-01-07 Fitting and Harness Inspection Full-body harnesses are the only form of body-wear to be used for fall

37 3. HIGH RISK ACTIVITIES Working at Heights MSC-OPS-WP Fitting and Harness Inspection Full-body harnesses are the only form of body-wear to be used for fall protection/fall arrest. It is very important to have a proper fitting harness throughout the entire course of a work shift. Do not allow your harness to become loose or slack.

3. HIGH RISK ACTIVITIES Calculating Fall Arrest Working at Heights MSC-OPS-WP-01-07 Note: If the risk is fall

38 3. HIGH RISK ACTIVITIES Calculating Fall Arrest Working at Heights MSC-OPS-WP Note: If the risk is fall factor 2 (i.e. the worker is anchored at foot level) with a max 2m lanyard then: Total clearance required (RD) is 6.75m

3. HIGH RISK ACTIVITIES Lifting and Slinging Lifting and Slinging MSC-OPS-WP-04-06 Lifting Gear must only be used for its designed purpose Safe Working Load (SWL) is the maximum working load for that

39 3. HIGH RISK ACTIVITIES Lifting and Slinging Lifting and Slinging MSC-OPS-WP Lifting Gear must only be used for its designed purpose Safe Working Load (SWL) is the maximum working load for that piece of equipment Always inspect all lifting devices prior to lifting. Check for: Signs of stretching in wire rope slings Broken Wires must not exceed 10% of total wire Corrosion (red oxide powder) between valleys of wires Kinks, knots and fractures Crushed/jammed strands caused by mechanical damage

3. HIGH RISK ACTIVITIES Lifting and Slinging MSC-OPS-WP-04-06 Lifting and Slinging Equipment Wire Rope Sling Chain and

assemblies must be made from the same grade and type of chains If a single broken wire is found near this equipment,

Shackles Flat Webbing & Round Synthetic Slings Swift Lift Clamps Dee Shackle attaches sling eye to eyebolt, Bow

40 3. HIGH RISK ACTIVITIES Lifting and Slinging MSC-OPS-WP Lifting and Slinging Equipment Wire Rope Sling Chain and Chain Sling Assemblies Metal Sockets, End Fittings / Machine Splices Most commonly used tackle All chain sling assemblies must be made from the same grade and type of chains If a single broken wire is found near this equipment, it must be discarded. Hooks Must be marked with SWL, damage or wearing > 10% must be discarded. Shackles Flat Webbing & Round Synthetic Slings Swift Lift Clamps Dee Shackle attaches sling eye to eyebolt, Bow Shackle attaches 2 or more sling eyes to lifting hook Susceptible to damage, care must be taken with storage. Attachment points must not be worn or damaged

3. HIGH RISK ACTIVITIES When to use a Dogger Lifting and Slinging MSC-OPS-WP-04-06 Dogging Work definition: a) the application of slinging techniques, including the selection and inspection of

41 3. HIGH RISK ACTIVITIES When to use a Dogger Lifting and Slinging MSC-OPS-WP Dogging Work definition: a) the application of slinging techniques, including the selection and inspection of lifting gear, to safely sling a load; or b) the directing of a plant operator in the movement of a load when the load is out of the operator's view A Dogger is required if Judgement needs to be made on: What slinging technique is appropriate or The selection or inspection of lifting gear in order to safely sling a load i.e., lifting points and slings aren t predetermined and inspected and/or The load to be lifted is out of the operator s view.

42 3. HIGH RISK ACTIVITIES Loading Vehicles Incorrect positioning of the load on a vehicle can result in a significant safety risk. Correct Loading Techniques include: Ensure vehicle is appropriate for load Plan the load arrangement and suitable positioning (central and over load bearing axles where possible) Use slings and chains rather than forks for large and awkward items Weak crushable items should be placed behind (or on top of) strong items to prevent damage Heavy loads should not be placed against the headboard Loading and Unloading MSC-OPS-WP-04-03

3. HIGH RISK ACTIVITIES Load Restraints Ratchet Binder

Over-Centre Binder Not to be used on any site Bungee

Suitable load restraints should be used at all times

43 3. HIGH RISK ACTIVITIES Load Restraints Ratchet Binder May be used as an alternative for securing chains Over-Centre Binder Not to be used on any site Bungee Cord ( Occy Straps) Not to be used to tie down loads. Suitable load restraints should be used at all times Straps, chains or rope may be used, depending on the load type and transport conditions. Chains and approved straps are the preferred tiedown restraints for heavy loads.

44 3. HIGH RISK ACTIVITIES Knowledge Check: 3. High Risk Activities 1. When should you place yourself in the line of fire? Never! You are at risk in the line of fire, never place yourself in the line of fire 2. Are you allowed to enter and work alone in a Confined Space? No. An entry attendant (stand-by person) is required to monitor the environment 3. What distance from an open edge would be considered Working at Heights? 2 metres 4. When is a Dogger required to assist with a lift? When judgement is required to decide on the lifting technique and/or lifting equipment selection 5. What type of load restraint is a suitable alternative for securing chains? Rachet Binder

45 4. ISOLATION AND TAGGING Isolation and Tagging Isolating Energy Sources Isolation Points Isolation Tags Personal Locks Three Steps of Isolation

4. ISOLATION AND TAGGING Isolating Energy Sources Work Practice definition: Removal of the energy source from plant/equipment to prevent accidental energisation Why do we Isolate?

46 4. ISOLATION AND TAGGING Isolating Energy Sources Work Practice definition: Removal of the energy source from plant/equipment to prevent accidental energisation Why do we Isolate? Common Energy Sources To protect people working on plant and equipment from: Energy sources when working on or servicing plant/equipment Any faulty or otherwise damaged plant/equipment To prevents damage to equipment and the environment

4. ISOLATION AND TAGGING Isolation Points: Battery Isolation

Battery Isolation ( ) If the nature of the work requires all

Starter Motor Isolation ( ) If the nature of the work

47 4. ISOLATION AND TAGGING Isolation Points: Battery Isolation ( ) Isolates all power and renders the machine inoperable Battery Isolation ( ) If the nature of the work requires all power to be turned off and the machine to be inoperative Starter Motor Isolation ( ) If the nature of the work requires the machine to have power and the systems of the machine to be active

person DO NOT OPERATE Removal: ONLY by Tag

progress Removal: Person who placed it on

Protects the Machine DO NOT OPERATE Removal:

Information Tag: Provides information on

48 4. ISOLATION AND TAGGING Four Isolation Tags: Personal DANGER Tag: Protects the person DO NOT OPERATE Removal: ONLY by Tag owner Testing Tag: Alerts crew testing is in progress Removal: Person who placed it on completion of task Out of Service Tag: Protects the Machine DO NOT OPERATE Removal: Person carrying out repairs or Supervisor Information Tag: Provides information on defects Removal: replaced with OUT OF SERVICE Tag upon return to Workshop

dependant on work site and group division.

49 4. ISOLATION AND TAGGING Personal Locks Trailer Bay Mechanics CFC Plant Fitters Contractors Plant Boiler Makers Different coloured locks are used dependant on work site and group division. CFC Plant Off-Road Workshop all fitters use a RED personal isolation lock, in which they control and store personally.

50 4. ISOLATION AND TAGGING Physical Lock out Physical lock outs are used when plant/equipment don t have lockable isolation points. Dolly Eye lock out Visual Lock out of Steering wheel King Pin Lock-out

51 4. ISOLATION AND TAGGING Isolation: The Three step Process Step 1: Identify Step 2: Isolate Step 3: Remove Maintenance/Testing Complete Unauthorised removal of Tags will result in disciplinary action

4. ISOLATION AND TAGGING Isolation in Use Work to be Done Required action Battery Isolation ( / ) Starter Motor Isolator ( Mechanical repair Full Isolation Locked and

52 4. ISOLATION AND TAGGING Isolation in Use Work to be Done Required action Battery Isolation ( / ) Starter Motor Isolator ( Mechanical repair Full Isolation Locked and Tagged Shut down Pre-start, electrical testing Starter motor Isolation Unlocked & ON Locked and Tagged with Test tag Operable machine Live Equipment Unlocked & ON Unlocked & ON

53 4. ISOLATION AND TAGGING Knowledge Check: 4. Isolation and Tagging 1. Name 3 sources of energy: Electricity, Mechanical, Pneumatics, Gas, Hydraulics, Water, Chemical/Coolant, Steam 2. When would a starter motor isolation point be used? When the nature of the work requires the machine to have power (i.e., performing a pre-start on a machine checking that the control systems are functioning) 3. Who may remove an Out of Service Tag? Removal by Person carrying out the repairs OR Authorised Supervisor 4. What colour personal locks are used by the CFC Plant Department? Red personal locks 5. What are the three steps of Isolation? Step 1: Identify Step 2: Isolate Step 3: Remove

54 Some Golden Rules to live by: Wrapping Up You have the right to if you feel unsafe MAKE SURE YOU ARE COMPETENT TO CARRY OUT THE TASK IF IN DOUBT: Questions?

55 Fin

FATAL AND SEVERE RISK PROGRAM

FATAL AND SEVERE RISK PROGRAM LEADER SESSION FALL FROM HEIGHTS Only do the task if it can be done safely FALL FROM HEIGHTS OUR COMMITMENT LIFE SAVING BEHAVIOUR: I WILL ALWAYS USE ADEQUATE PROTECTION WHERE