Department Document Number

CC WATER MANAGEMENT CC-00018-WI-OP-0013_Rev 9

Section Title
SAFE WORK INSTRUCTION Removal of Bore Pump on Permaglass / FRP riser

Removal of Bore Pump on Permaglass/ FRP Riser

PURPOSE
To provide the required information to all dewatering personnel to remove a submersible pump
from a bore hole in a safe and consistent manner and to provide a clear step by step process in
which the task is to be followed.

SCOPE
This Safe Work Instruction shall relate to all Mine personnel who are required to remove a bore
pump in a consistent and safe manner. A copy of this information is to be printed off and
available at the job site at all times during the undertaking of this task. Personnel shall comply
with Fortescues Life Saving Choices. This Safe Work Instruction supersedes all previous Safe
Work Instructions and Site Notices.

AREA
 All Areas Christmas Creek Mine Site

REFERENCES / ASSOCIATED DOCUMENTATION

 100-PR-SA-1035 Life Saving Choices
 100-PR-SA-1028 Isolation & Tagging
 100-PR-SA-0039 Personal Protective Equipment
 100-FR-RK-0004 Job Hazard Analysis
 100-FR-RK-0005 5 Step
 100-PR-SA-0046 Emergency Response Procedure
 CC-00039-WI-OP-0002 Trailer Hitching and Towing
 100-PR-SA-0018 Crane Management
 CC-PL-SA-0005 Christmas Creek Mining Traffic Management Pla

REQUIREMENTS
LIFE SAVING CHOICES
The twelve choices define the standards that shall be met in our workplace to ensure safe
systems of work, and to guide you in making the correct decisions. The choices you make, every
single day, are fundamental to creating a safe operation. The non-negotiable choices are:
LIFE SAVING CHOICES
Secure tools and barricade work areas to prevent dropped
Use fall protection when working at height – 2x2.
objects.

Maintain 3 metres from track and only work within authorisation

Never walk or work under a suspended load.
limit.

Follow Lightning instructions at work.

Only inflate tyres in an approved tyre safety device.

When driving wear a seat belt and obey speed Obtain authorisation prior to entering confined space.
limits.

Verify isolations and confirm stored energy has been controlled

Stop at stop signs and rail crossings.
before work begins.

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REMOVAL OF BORE PUMP ON PERMAGLASS COLUMN
CC-00018-WI-OP-0013_Rev 9
 Department Document Number
CC WATER MANAGEMENT CC-00018-WI-OP-0013_Rev 9
Section Title
SAFE WORK INSTRUCTION Removal of Bore Pump on Permaglass / FRP riser

Obtain authorisation to enter explosives exclusion zones.

Wear a PFD when working above water.

PERSONAL PROTECTIVE EQUIPMENT (PPE)

JOB SPECIFIC RESOURCES

Barricading  Sentry & Sentry Board  Fire Blankets  Phones 
Drinking Water  Running Water  Voltage Reducer  Extinguishers 
Warning Signs  Fire Watch  Radio  First Aid Kit 
JOB SPECIFIC EQUIPMENT
Truck with Extendable Pump unit including
HIAB Crane or other

2 x Stilsons  Set of Allen Keys  column & bore-head
plate

Crane as available
Lift Clamps  Bore-head Lifting Lug  25mm & 32mm PVC
Conduit, Pump Adaptor  Correct size spanner for
nut/bolts required

Slip Plate  Conduit cutters  Cable controlling/
handling device
 Double Leg Chains 

DESCRIPTION OF WORK
The core of the Dewatering Operations across Christmas Creek is the system of bore pumps, which
lower the local water table to a level close to, or below the level of the bottom of the open pit operations.
The water taken out of the ground is piped to a location further from the active mining area and then re-
injected back into the ground. The amount of water pumped from underground must comply with
dewatering legislation, licensing and FMG standards. This requires that the pumps be installed and
removed correctly. This procedure outlines the steps required to remove bore pumps consistently, while
maintaining a high level of safety.

JOB STEP AND CONTROL METHODS

No. Job Steps
Hazards Controls Image or Diagram
1 Create a clear plan of the task.

 Weather, ground  A 5 step / take control shall

conditions and task scopes be completed before each
change daily. task to identify any
immediate hazards.
 Energised equipment
poses a major hazard.  Ensure any source of
electricity has been
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REMOVAL OF BORE PUMP ON PERMAGLASS COLUMN
CC-00018-WI-OP-0013_Rev 9
 Department Document Number
CC WATER MANAGEMENT CC-00018-WI-OP-0013_Rev 9
Section Title
SAFE WORK INSTRUCTION Removal of Bore Pump on Permaglass / FRP riser

removed/ isolated from the

pump.
 Stored energy exists within
the bore-field system.  Isolate and lock any
potential source(s) of water
to the bore headworks/
pump. Release stored
energy and try test.

 Review any procedures /

 Other hazards exist SWIs associated with the
surrounding the given task. task.

 If the task deviates away

 The task may move from from this SWI a JHA shall
the intended scope of be completed and approved
work. by your Supervisor on the
job site.

 Only personnel who are

 Without the required trained, assessed and
skillset for the task, the authorised shall perform this
individual poses a risk to task, inclusive of correct
themselves and others driving permits.

2 Set up the Truck, Cable trailer, Crane or Hiab

 Machine wear can lead to  Complete pre-start inspection

equipment damage or loss of all equipment (in
or injury and death. accordance with the
checklists). This checklist
must be documented and
handed in to your supervisor.

 Personnel operating  The operator of equipment

machinery that have not must be trained, assessed
been properly trained pose competent and hold current
a threat to themselves and ticket.
colleagues.

 Other personnel may enter  Barricade area ensuring

work area. enough room for works

 Equipment working outside  Position the cable trailer and

of their operational range crane so as to work within
is at risk of catastrophic restrictions of the unit and
failure. follow the Cranes and Lifting
Equipment Procedure.

 Cables attached to the  Position the cable trailer so

cable trailer associated that the work area is clear of
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REMOVAL OF BORE PUMP ON PERMAGLASS COLUMN
CC-00018-WI-OP-0013_Rev 9
 Department Document Number
CC WATER MANAGEMENT CC-00018-WI-OP-0013_Rev 9
Section Title
SAFE WORK INSTRUCTION Removal of Bore Pump on Permaglass / FRP riser

with the pump can pose a cables that could cause a trip
trip hazard. hazard.

 Damage to cable during  Use a strap or tape to attach

removal can cause the electrical cable to the
electrical hazards and drum on the cable trailer.
equipment failure. Keep plug free for electrician
to test.
 Line of fire and
suspended loads.
 Ensure all personnel are
aware of suspended load
 Unexpected machinery and to keep out of area.
movement.
 Install suitable wheel chocks
to truck and trailer also lower
stabiliser legs

3 Remove the bore headworks and drain water from

column.

 Stored energy due to  Isolate in accordance with

hydraulic pressure exists company policy
within operational bore
manifold systems.

 Using the incorrect tool for  Use correct size tooling and
the job is a known cause maintain control to prevent
of personal injury. slipping

 Musculoskeletal injury is  Use HIAB or crane to remove

caused by incorrect lifting the disconnected headwork’s
and poor posture when away from the work area to
undertaking tasks. prevent trip hazard

 Pinch and crush points  Operators are not to place

evident during this task hands between pipe work
and bore-head plate at any
time.

 Trip hazard/ cable damage  Remove Low Level probes

from conduit and store out of
work area to prevent damage
and/ or trip hazard.

 Uncontrolled movement of  Remove Torpedo from holder

“Torpedo” can cause injury with care ensure
to personnel in work area pendulum/swing area
between bore and cable
trailer is clear of personnel

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REMOVAL OF BORE PUMP ON PERMAGLASS COLUMN
CC-00018-WI-OP-0013_Rev 9
 Department Document Number
CC WATER MANAGEMENT CC-00018-WI-OP-0013_Rev 9
Section Title
SAFE WORK INSTRUCTION Removal of Bore Pump on Permaglass / FRP riser

 Water in column creates a  Lower torpedo down column

lot of weight. until it comes to rest on
“Break off pin”. Lift by hand
and drop, to shear pin and
drain water ensuring no
damage to pump

 Entanglement in cable for  Make sure the work area is

“Break off pin Torpedo”
 Loss of “Torpedo” down
column
clear of cable rope and use
the cable drum on cable
trailer to raise and lower the DON’T
torpedo.
USE
 Ensure “Torpedo is
connected securely to wire
rope with shackle, and check
condition of wire rope

 Incorrect storage of  Once “Torpedo” is removed

“Torpedo” can cause from column, store in holder,
uncontrolled movement disconnect wire rope form
and injury to personnel in “Torpedo” and secure wire
work area rope to frame with shackle

 Threaded Head plates are  Inspect head plate on

known to unscrew/ corrode removal and if not the bolt
causing equipment loss. through type exchange
before re-installation.

4 Attach lifting equipment to bore head, remove first

column(s) and place on flat ground, out of work area.

 Suspended load.  Always inspect the chains

for damage, wear ensure
they are compliant and
have the correct quarterly

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REMOVAL OF BORE PUMP ON PERMAGLASS COLUMN
CC-00018-WI-OP-0013_Rev 9
 Department Document Number
CC WATER MANAGEMENT CC-00018-WI-OP-0013_Rev 9
Section Title
SAFE WORK INSTRUCTION Removal of Bore Pump on Permaglass / FRP riser

tag. Only personnel who

are trained, licenced and
assessed shall operate
the crane and rig loads.

 Ergonomics of work
area and height of
casing  Magic frame is available
to raise working height
and assist with manual
 Cables and conduits handling
can become a trip
hazard if not attended  Operators to maintain a
when removing bore clean, clear work area
components. and make sure all cables
are clear of works.
 Visual/verbal
communications are  Be sure at least one
imperative to the safe operator on the ground
operation of overhead has a handheld radio to
lifting equipment. maintain contact with
crane operator. Maintain
line of sight with crane
operator and use clear
 Crush/pinch points hand signals.
exist during steps to
bore head plate  Never put yourself under
removal. a suspended load.
Always wear PPE and
use the correct tools for
 The Slip Plate is the the job.
only defence against
equipment dropping  Place the Slip Plate over
down the bore hole. the bore head and guide
the crane operator to
lower the clamp gently on
to the slip plate keeping
 A sharp blade is yourself out of the line of
necessary to remove fire.
the tape at FRP joins
and conduit.  Always wear gloves and
retain full control of
cutting implement.
 Removal of stainless
steel locking wire
requires use of pliers  Remove cable by
and may be hard to applying a steady pull
remove. Sprains, pressure to pliers. Do not
strains, stored energy tug or overexert. Have the
present. crane operator try
relieving pressure on
cable by slightly lifting or
lowering FRP. Use plier
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REMOVAL OF BORE PUMP ON PERMAGLASS COLUMN
CC-00018-WI-OP-0013_Rev 9
 Department Document Number
CC WATER MANAGEMENT CC-00018-WI-OP-0013_Rev 9
Section Title
SAFE WORK INSTRUCTION Removal of Bore Pump on Permaglass / FRP riser

 Entanglement in cables to lever cable on side of

in the event of pump, FRP.
column or chain failure
 Operator in control of
cable handling trailer to
raise cable at
approximately the same
rate as the crane is
 Inexperienced operator raising the column to
prevent slack in the cable.
 Ensure operator holds
appropriate competencies
for task.
o *Crane Operator
shall under no
circumstance
swing suspended
load over
personnel in the
task area.

5 Clamp the FRP and use the Slip Plate to support it within
the bore hole, remove second column and place on flat
ground (or stack) out of work area.

 Excessive lengths of  As the lengths of conduit are

conduit in and around the removed from the bore store
work area are a trip in an appropriate area.
hazard.

 Cutting of conduit requires  Disconnect and or cut conduit

a sharp-edged tool.
 Pump power cable and
sensor cables on the
ground in the work area
pose a trip hazard.
 Crush/pinch points exist
during steps to bore head
plate removal.
into manageable lengths and
place them out of the way of
the work area. Use the
correct tool for the job (pipe
cutter, hacksaw). PPE-
Gloves.
 Feed the power cable on to
the cable trailer drum and
setup sensor cables into a
neat coil out of the way of the
active work area or use
appropriate reel.
 Never put hands under a
suspended load. Always wear
PPE and use the correct tools
for the job.

 Fatigue, manual handling

 Actively rotate tasks to
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REMOVAL OF BORE PUMP ON PERMAGLASS COLUMN
CC-00018-WI-OP-0013_Rev 9
 Department Document Number
CC WATER MANAGEMENT CC-00018-WI-OP-0013_Rev 9
Section Title
SAFE WORK INSTRUCTION Removal of Bore Pump on Permaglass / FRP riser

minimise potential of injury,

excessive workloads and
fatigue.

 Heavy FRP can be broken to

5m lengths if needed.

 Use a sling or trolley to

minimise manual handling
when lowering FRP. Never
place any body parts under
the load when lowering.

6 Repeat process 5 until pump is visible.

7 Detach final length of FRP and wash pump using high
pressure washer.

 Line of fire  Be aware of any

possibilities of stored
energy whilst pulling last
components out of the
bore e.g. bent or jammed
conduits.

 Stay clear of the line of

fire of high-pressure
water.

 Suspended loads  Never walk under

suspended loads.

 High pressure water  Never spray water

towards genset, control
panel or other personnel.

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REMOVAL OF BORE PUMP ON PERMAGLASS COLUMN
CC-00018-WI-OP-0013_Rev 9
 Department Document Number
CC WATER MANAGEMENT CC-00018-WI-OP-0013_Rev 9
Section Title
SAFE WORK INSTRUCTION Removal of Bore Pump on Permaglass / FRP riser

8 Remove shroud and wash motor and screen using high

pressure washer.

 Line of fire.  Be aware of any possibilities

of stored energy whilst pulling
the last components out of
the bore e.g. bent or jammed
conduits.

 Suspended loads  When transporting pump to

resting location use a tag line.

 Pump cables pose a trip  Make sure cables are out of

hazard. the way of trafficable area.

9 Place pump on flat ground and remove FRP adaptor and

break-off pin (inspect adaptor and threads for corrosion).

 Crush/pinch injury.  Keep hands clear of line

of fire when removing
FRP adaptor.

 Use correct
lifting/handling techniques
if removing FRP adaptor
to retrieve break off pin.

 Pump may detach due  Inspect fittings for signs of

to excessive corrosion. corrosion and replace if
required.

 Call job into the electrical

team for test and
commissioning

10 House Keeping

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REMOVAL OF BORE PUMP ON PERMAGLASS COLUMN
CC-00018-WI-OP-0013_Rev 9
 Department Document Number
CC WATER MANAGEMENT CC-00018-WI-OP-0013_Rev 9
Section Title
SAFE WORK INSTRUCTION Removal of Bore Pump on Permaglass / FRP riser

 Confusion leading to lost  Ensure Removal Sheet/

assets Install Sheets and any other
associated asset tracking
forms are on hand and
completed for works.

 Excessive downtime for  Ensure de-isolation process

equipment is followed. Remove Personal
Locks once works are
completed.

 Incorrect housekeeping  Pick up all tools that were

can cause accidents and used on the task and store
incidents. them correctly.

 Remove any barricades that

have been erected.

 Communicate to your
supervisor that the task has
been completed (if required).

 Ensure that all rubbish has

been cleared up and
disposed of correctly.

 Check area for hydrocarbon

spillages

11 Hazard Reporting
 Hazard reporting is  If any hazard/s are identified
essential to maintaining a during this task either remove
safe workplace; operators the hazard/s or isolate the
shall follow these simple Hazard/s.
instructions to complete the
given task.  DO NOT put yourself or
others in danger.

 Complete a hazard report

and hand it into your direct
supervisor.

 If the SWI is not valid (not

valid meaning the SWI
contains incorrect
information) report to
supervisor for “simple change
management” immediately.

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REMOVAL OF BORE PUMP ON PERMAGLASS COLUMN
CC-00018-WI-OP-0013_Rev 9
 Department Document Number
CC WATER MANAGEMENT CC-00018-WI-OP-0013_Rev 9
Section Title
SAFE WORK INSTRUCTION Removal of Bore Pump on Permaglass / FRP riser

I have received, read, understood and shall comply with this Safe Work Instruction for Removal of
Bore Pump.

Full Name: ID Number:

Signature: Crew/Pit:

Company: Department:

Date: ______ / ______ / _________

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REMOVAL OF BORE PUMP ON PERMAGLASS COLUMN
CC-00018-WI-OP-0013_Rev 9