Job Safety & Risk Assessment Forms Plant: Freeport. Job: Maintenance. Component: MCU's Review Date

Job Safety & Risk Assessment Forms Page 1 Of 14 JSRA No.
13
Plant: FREEPORT. Job: MAINTENANCE. Component:

MCU’s Review Date: / /
Work Step Potential Hazard & Effects L C R Possible Elimination/Migration Residual Hazard L C R
Measures (How can people still hurt
themselves)
Pump Manual Handling. The pump is in an B 3 35 Always remove the pump from its E 3 3
Maintenance awkward position and is heavy. Back mounting.
injuries can occur
Use a lifting aid where possible. The
gantry crane and wheel barrow are
always available.
Two operators should lift it together

where lifting is necessary.
Lift with your knees not your back.
Wheel it to the workbench and work

on it there so that you don’t have to
be bent over it.
Crush injuries from MCU rolling or C 5 45 Use wheel chocks and lower E 3 3
dropping pump on fingers and toes jacklegs.
Place on level ground prior to

starting
Tag the MCU with danger tag and

Isolation switch in the OFF position
themselves)
Ware correct PPE (Safety Boots and
Gloves).
Clean Grease, Water and Emulsion

off pump before lifting so that the
pump wont slip out of your hands.
Co-ordinate lifting and walk in step.
Damage to limbs from incorrect tool C 1 3 Use correct tools correctly & wear E 1 1
usage gloves when using hand tools.
Slip and Trip Hazards can cause B 3 35 After and before working in the E 3 3
Brakes, Cuts and Abrasions. crane area check that there are no
trip hazards and clean up EP spills
(House Keeping).
Always look where you are walking

and clear a path prior to carrying
weight a distance.
Use a manual handling aid where

possible.
Explosions. Although Emulsion is not D 6 40 DO NOT USE CLEANING E 4 4

classed as impact sensitive it is still an AGENTS THAT ARE NOT
EXPLOSIVE. RECOMMENDED FOR USE
AROUND EXPLOSIVES AND
WHEN IN DOUBT DON’T USE
themselves)
Only qualified Pump Mechanics are
to work on pumps.
Clean all components thoroughly.
Make sure all brass fittings are

replaced with Stainless ones due to
Copper Tetra Amine Nitrate build
up. (See Eng Alert on the subject).
Don’t force parts into place with

steel instruments (Bashing).
Don’t mix chemicals as they might

react with each other.
Read Chemical Safety Data Sheets

in the Chemical Register.
Skin and Eye irritation can cause pain A 2 30 Ware correct PPE (Gloves, Safety E 2 2
and disorders such as Dermatitis. Glasses and full length sleeves and
Emulsion is an irritant. leggings)
If you are prone to rashes use a

cream before and after working with
Emulsion.
ALWAYS COMPLETE A
GENERAL CLEARANCE
CERTIFICATE AS THIS WILL
HELP HIGHLIGHT ANY
POSSIBLE HAZARDS.
themselves)
EP Tank and Confined space related hazards could C 5 45 COMPLETE CONFINED SPACE E 5 9
piping kill. Due to unknown gas ENTRY CLEARANCE
Maintenance contaminants or lack of oxygen. CERTIFICATE TO HIGHLIGHT
ANY POSSIBLE HAZARDS.
Steam clean tank and piping

thoroughly.
Carry out the required gas testing.
Have a stand by competent operator.
Safety lifting equipment should be

worn while in tank.
Enter confined spaces only if

absolutely necessary.
Explosions can cause death and C 6 51 DO NOT USE CLEANING E 5 9

serious injury. AGENTS THAT ARE NOT
RECOMMENDED FOR USE
AROUND EXPLOSIVES AND
WHEN IN DOUBT DON’T USE
Clean all components thoroughly.
Make sure all brass fittings are

replaced with Stainless ones due to
Copper Tetra Amine Nitrate build
up. (See Eng Alert on the subject).
themselves)
Don’t force parts into place with
steel instruments (Bashing).
Don’t mix chemicals as they might

react with each other.
Read Chemical Safety Data Sheets

in the Chemical Register.
Welding will only be carried out in a

designated hot work area. By a
qualified welder.
THE PART BEING WELDED

WILL BE REMOVED IF AT ALL
POSSIBLE AND THOROUGHLY
CLEANED.
A HOT WORK PERNIT MUST BE

COMPLETED PRIOR TO
STARTING AND ALL
CONDITIONS ADHEARED TO.
Skin and Eye irritation can cause pain Ware correct PPE (Gloves, Safety
and disorders such as Dermatitis. Glasses and full length sleeves and
Emulsion is an irritant. leggings)
If you are prone to rashes use a

cream before and after working with
Emulsion.
themselves)
Crush injuries can occur from C 4 24 If lifting the tank or frame off the E 4 4
dropping heavy equipment. MCU use only lifting equipment that
is correctly stamped with SWL and
is able to lift the weight.
Attach hooks and chains correctly

and only qualified operators are to
use lifting equipment.
Don’t stand under equipment being

lifted or guide with your hands. Use
ropes to steady the load.
MCU Crush injuries from MCU rolling or Use wheel chocks and lower
Engine and dropping heavy equipment on body jacklegs.
Hydraulics parts
starting


Gloves).

off pump before lifting so that the
pump won’t slip out of your hands.
Co-ordinate lifting and walk in step
Be aware that releasing hydraulic

pressure can cause parts to move
downward.
themselves)
Do not rely on Jack or Jack legs only
to support the MCU while working
underneath it.
Pressurised Hydraulic Oil can cause B 5 60 Don’t work on pressurised sections E 5 9

loss of eyesight severe Necrosis of the of the hydraulics. If unsure how to
skin and can kill if injected into the depressurise the area being worked
blood stream. Hot hydraulic oil can on ask your supervisor or check the
burn JCB Maintenance manual.
Allow the Hydraulic Oil to cool

down before working on it.
ALWAYS WEAR CORRECT PPE

FOR THE JOB (CHECK THE RED
BOOK IF UNSURE).
Damage to limbs from incorrect tool B 3 35 Use correct tools correctly & wear E 3 3
Slip and Trip Hazards can cause After and before working in the
Brakes, Cuts and Abrasions. crane area check that there are no
oil and grease (House Keeping).

weight a distance.
Use a manual handling aid where

possible.
themselves)
Making modifications to equipment B 5 60 Do not make modifications without E 4 4
can be hazardous to other users first letting your Supervisor know
and then completing an AA if
necessary.
Working on Explosions can be caused by heating, C 6 51 Remove all explosives before Residual Emulsion in E 5 9
the basket hitting or leaving Explosives on the working on the MCU. closed sections
arrangement platform while working on it.
and parts Clean the whole MCU thoroughly
before working.
Remove parts to work on where

possible.
If carrying out hot work complete a

hot work permit (Only by a person
with Clearance Certificate
Accreditation).
HOT WORK MUST ONLY BE

CARRIED OUT IN A HOT WORK
AREA.
Crush Injuries can occur from the B 5 60 Use the Basket Support leg at all
basket lowering while working under times while working under it.
it. Or catching fingers in chains. Also
by the MCU moving while working Reduce your time under the basket
around it. by removing the part being worked
on and taking to the workbench or
workshop for further work.
Isolate the MCU and TAG steering.

themselves)
Use wheel chocks and lower
jacklegs.

starting.


Gloves).

off parts before lifting so that the
parts won’t slip out of your hands.
Co-ordinate lifting and walk in step
Be aware that releasing hydraulic

pressure can cause parts to move
downward.
If testing the hose pusher make sure

everyone is well clear prior to
operation.
Heavy jobs to be carried out by

Tamrock under an Orica clearance
completed by someone accredited to
complete clearances needed for the
job.
Plant: FREEPORT. Job: MAINTENANCE. Component: Gantry Crane. Review Date: / /
themselves)
Electrical Electrocution can be fatal C 5 45 UNDER NO CIRCUMSTANCES E 5 9
Maintenance IS ELECTRICAL MAINTENANCE
TO BE CARRIED OUT BY ORICA
OPERATORS.
THIS WILL BE DONE BY A

QUALIFIED SITE ELECTRICIAN
Electrical work done by a contractor

will be carried out using the Orica
Clearance system.
Electrician’s Qualifications to be
checked out prior to starting work.
Falls from man cage while working C 5 45 The qualified Electrician will ware a E 4 4
on the Gantry Crane can be fatal lanyard and full body harness while
working on the Crane.
Where possible dismantle and work

on the component being repaired on
the ground or workbench. This will
reduce time spent at height.
No climbing on the edge of the man

cage. Raise and lower as required.
Make sure the Lanyard is attached to

the cage. In a secure location on the
cage.
themselves)
General Falls from man cage while working C 5 45 The Operator will ware a lanyard E 4 4
Maintenance on the Gantry Crane can be fatal. and full body harness while working
greasing, on the Crane.
changing
cable, Where possible dismantle and work
painting etc on the component being repaired on
the ground or workbench. This will
reduce time spent at height.
No climbing on the edge of the man

cage. Raise and lower as required.
Make sure the Lanyard is attached to

the cage. In a secure location on the
cage.
Electrocution from live or bared C 5 45 ALWAYS ISOLATE THE CRANE E 4 4

wires. AT THE ELECTRICAL
ISOLATION SWITCH AND TAG
OUT WHILE WORKING ON IT.
Check first for bared wires and

inform the Supervisor if any are
found. UNDER NO
CIRCUMSTANCES IS AN
ATTEMPT TO BE MADE TO FIX
IT YOURSELF.
THIS WILL BE DONE BY A

QUALIFIED SITE ELECTRICIAN
When testing check the following.
themselves)
Pre Start is correctly carried out
(Check that the concertina cable is
not frayed or tangled).
Make sure that the cable does not

get caught under the rail runners and
short out.
Crush injuries caused by rolling crane C 3 14 ALWAYS ISOLATE THE CRANE

while working. AT THE ELECTRICAL
ISOLATION SWITCH AND TAG
OUT WHILE WORKING ON IT.
When testing crane do so from

ground level.
Rest the hook on the ground while

working on the upper parts.
usage. gloves when using hand tools.
Slips Trips and Falls After and before working in the

crane area check that there are no
(House Keeping).

weight a distance.
Plant: FREEPORT. Job: MAINTENANCE. Component: Getman Review Date: / /
themselves)
General Vehicle movement while doing C 5 45 Use wheel chocks and E 5 9
Maintemance checks causing operator to be crushed Place on level ground prior to
or injured starting.
Tag the Getman with danger tag and

ALWAYS DEPRESSURISE HYDR
Falling from Getman while getting in B 2 12 Use correct 3-point contact E 2 2

and out causing brakes, bruising, cuts technique.
and abrasions.
Make sure your Safety Boots are in
good order.
That the non-slip tape on the steps is

ok.
Pressurised Hydraulic Oil can cause B 5 60 Don’t work on pressurised sections E 5 9

loss of eyesight severe Necrosis of the of the hydraulics. If unsure how to
skin and can kill if injected into the depressurise the area being worked
blood stream. Hot hydraulic oil can on ask your supervisor or check the
burn JCB Maintenance manual.
Allow the Hydraulic Oil to cool
down before working on it.
themselves)
ALWAYS WEAR CORRECT PPE
FOR THE JOB (CHECK THE RED
BOOK IF UNSURE).
Actions By Whom By when Date Completed
Participants: Nick Kramer Reviewed by: Date:

Job Safety & Risk Assessment Forms Plant: Freeport. Job: Maintenance. Component: MCU's Review Date

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Job Safety & Risk Assessment Forms Page 1 Of 14 JSRA No.

Plant: FREEPORT. Job: MAINTENANCE. Component:

Two operators should lift it together

Lift with your knees not your back.

Wheel it to the workbench and work

Place on level ground prior to

Tag the MCU with danger tag and

Clean Grease, Water and Emulsion

Co-ordinate lifting and walk in step.

Always look where you are walking

Use a manual handling aid where

Explosions. Although Emulsion is not D 6 40 DO NOT USE CLEANING E 4 4

Clean all components thoroughly.

Make sure all brass fittings are

Don’t force parts into place with

Don’t mix chemicals as they might

Read Chemical Safety Data Sheets

If you are prone to rashes use a

Steam clean tank and piping

Carry out the required gas testing.

Have a stand by competent operator.

Safety lifting equipment should be

Enter confined spaces only if

Explosions can cause death and C 6 51 DO NOT USE CLEANING E 5 9

Clean all components thoroughly.

Make sure all brass fittings are

Don’t mix chemicals as they might

Read Chemical Safety Data Sheets

Welding will only be carried out in a

THE PART BEING WELDED

A HOT WORK PERNIT MUST BE

If you are prone to rashes use a

Attach hooks and chains correctly

Don’t stand under equipment being

Tag the MCU with danger tag and

Ware correct PPE (Safety Boots and

Clean Grease, Water and Emulsion

Co-ordinate lifting and walk in step

Be aware that releasing hydraulic

Pressurised Hydraulic Oil can cause B 5 60 Don’t work on pressurised sections E 5 9

Allow the Hydraulic Oil to cool

ALWAYS WEAR CORRECT PPE

Always look where you are walking

Use a manual handling aid where

Remove parts to work on where

If carrying out hot work complete a

HOT WORK MUST ONLY BE

Isolate the MCU and TAG steering.

Place on level ground prior to

Tag the MCU with danger tag and

Ware correct PPE (Safety Boots and

Clean Grease, Water and Emulsion

Co-ordinate lifting and walk in step

Be aware that releasing hydraulic

If testing the hose pusher make sure

Heavy jobs to be carried out by

THIS WILL BE DONE BY A

Electrical work done by a contractor

Where possible dismantle and work

No climbing on the edge of the man

Make sure the Lanyard is attached to

No climbing on the edge of the man