Mobile Heavy Equipment Recovery Standard Procedure

The purpose of this procedure is to safely recover mobile equipment that may have been bogged, overturned, suffering from mechanical/structural failure, slipped over an edge or into a culvert, or similarly immobilized.

It provides instruction for recovery operations that require the use of heavy mobile recovery equipment, although some of the general safety principles may apply to simpler recovery operations.

Recovery Objectives and Approach:

General objective of all recovery operations is to return equipment safely to operational service, either directly from recovery or after repairs (either in-field or at the workshop). The recovery of all mobile plant should be undertaken using the risk management framework.

Roles & Responsibilities

Project director / manager have overall responsibilities for the implementation of this standard safety procedure.

The equipment operator is responsible for advising radio control and the Supervisor, as soon as possible, that equipment recovery may be necessary; and if safe to do so, ensuring equipment is safely immobilized lock-out and out of harms way – protect life before mobile plant.

Operation and Maintenance Supervisors are responsible for assessing the recovery site and safely coordinating any recovery effort that may be required; and if equipment has been involved in a reportable incident, obtaining permission to move it – do not recover equipment involved in a reportable incident until permission has been granted.

Terms & Definitions

Some of the more important terms used in this document are defined below:

Competence (By virtue of knowledge, training, experience and certification). The demonstrated skill and knowledge required to carry-out the task to a standard necessary, for the safety and health of persons.

JSEA: Job Safety and Environmental Analysis – a risk management tool.

Mobile Plant and Equipment: Means plant capable of being moved under its own power. (Self-Propelled)

PPE: Personal Protective Equipment

Recovery Area: Area surrounding the recovery site and being used by recovery equipment / team.

Recovery Site: Location of disabled mobile equipment.

Recovery Team: Personnel assembled to undertake the recovery effort. Its constitution depends on the complexity of the recovery process.

Reportable Incident: Are incidents required by law to be reported to the Governing Bodies. Check the country legislation for specific events that must be reported.

SWL (Safe Working Load): Means the maximum load that may be applied to the sling, or lifting component, under the particular conditions of use.

Mobile Equipment Recovery Process

Planning

a) A recovery team should be established and may include the maintenance and shift supervisors, safety, any logistics personnel representation, others with recovery experience and operators involved in the recovery.

b) An assessment should be conducted to determine whether or not the level of risk associated with recovery operation requires the fuller analysis of risk provided by a JSEA. Risk levels will range from high to low depending upon the context and complexity of the recovery operation.

c) Do not become complacent during assessment and planning activities because similar recoveries have previously been completed successfully. Focus effort on the current recovery, the current circumstances and the current risk.

d) A work area inspection of the recovery site and recovery area should also be conducted prior to completing the JSEA.

e) The JSEA will be conducted by the team responsible for the recovery using HSE JSEA Worksheet. Additional workers that may subsequently be seconded to the recovery team should review and sign on to the JSEA.

f) The JSEA should identify the steps in the recovery task, identify the hazards at each step, and specify control measures to reduce the risk to an acceptable level. Specific matters to be considered that may include: ** Note: This is not an exhaustive list. **

i. location – remote area, near pit wall, on ramp or haul road;

ii. overhead / underground services;

iii. site security;

iv. maintaining safe area around recovery operations/restricting personnel;

v. stability of plant or equipment to be recovered;

vi. stability of the surrounding area;

vii. size / mass of equipment;

viii. mass of the load to be recovered, moved or secured;

ix. any special lifting or towing requirements;

x. tools & equipment to be used for the recovery;

xi. method or sequence required for the recovery and any controls necessary;

xii. communication within recovery team and with nearby workers;

xiii. communication systems;

xiv. repair at recovery site vs at workshop;

xv. safe transport / escort of recovered equipment to another area, eg, workshop;

xvi. safe transport / escort of equipment to be used in recover operation to / from the recovery area;

xvii. traffic;

xviii. environmental conditions e.g. visibility, weather, lighting;

xix. number and competency of persons to be involved; and

xx. recovery near or over body of water.

g) A crucial part of the planning process is to identify and acquire the appropriate equipment and tools required. Maintenance should be involved. Equipment and tools selected should be suitable for the type of recovery to be undertaken and the mass of the equipment being recovered.

h) Plan all crane lifts to be undertaken. Depending upon the category of lift being undertaken a Daily Lift Log, Lift Evaluation Form or Critical Lift Plan may need to be completed and different levels of approval obtained in compliance with Lifting Operations procedure.

i) Plan all transportation routes, paying particular attention to managing obstacles and potential hazards. For example, traffic density, high / wide loads, safe clearance distances at overhead powerlines, inclines / declines (particularly if towed vehicles does not have steering / braking functions), narrow junctures, excavations, etc.

j) All personnel involved in recovery should be briefed about the recovery steps agreed in the JSEA, including, hazards and controls, individual tasks, equipment, roles and responsibilities and signed off.

k) Inform nearby workers and other relevant people of the impact the recovery operation may have on them, for example, changed traffic arrangements.

Setting up for Heavy Equipment Retrieval

Obtain any necessary permits, for example, working in the vicinity of power, working at heights, permission to transport high / wide loads etc.

A further work area inspection should be conducted of the recovery site and recovery area. Any new identified hazards should be controlled and the JSEA reviewed, if necessary.

Check that the recovery site and recovery area are isolated, secure and that traffic / pedestrian access to and around them is controlled – for example, barriers, tape, advance warning signs, berms / windrows, restricted area signs, post guards etc.

The recovery area should be large enough to safely handle the size of the recovery team and the size and type of recovery equipment. For example, if a crane is being used, its swing radius must fall within the barricaded area.

Check that operators and the recovery team have the appropriate PPE, are fit-for-work and not fatigued – they must inform the Supervisor if feeling tired or on prescription medication that may affect mental alertness.

Assemble required equipment and tools in the recovery area and conduct pre-start safety checks.

Transport cranes to the recovery area. Set up and demarcate the crane-use area at the recovery site. Conduct pre-start safety checks in accordance with requirements mentioned in Crane Operations and  Lifting Operations procedures. Record this inspection on appropriate documentation.

Inspect all lifting slings, chains etc. to confirm they are not damaged and have current certified tags attached – do not use chains, slings, wire rope etc. if their SWL identification tag is missing or color coding is incorrect.

Confirm the SWL of the crane and lifting accessories are suitable for the task – do not operate a crane or use lifting gear outside of their SWL or color coding is incorrect.

Confirm that the tow vehicle and transport vehicle e.g. trailer if being used are safe-to-use, of appropriate size for the task and registered if going on a public road.

Rope, slings, chains to be used for towing should be checked to ensure they adequately rated for the task – do not use lifting chains/slings for towing purposes. Also check the adequacy of chains and ropes to be used to secure any load.

All safety checks on equipment to be used are to be performed by appropriately licensed and competent personnel – only operate / check equipment for which you have an appropriate license.

Inform nearby workers and other relevant people that retrieval is imminent.

Performing the Equipment Retrieval

Recovery activities should be undertaken in accordance with the JSEA. Controls must be reviewed if new hazards / issues emerge during retrieval.

Keep non-essential personnel away from the recovery area and recovery site during retrieval.

Operate the crane in accordance with Crane Operations – never swing the load over personnel and never leave loads hanging.

All equipment used during retrieval must be operated in accordance with required training, the manufacturer’s manual and the requirements of relevant project safety instructions.

Use the vehicles manufacture tow point to attach slings, chains etc. – avoid using the axle as a tow point unless advised by workshop mechanic.

Escorts are required when towing or transporting equipment away from the recovery site. Escort vehicles are required at the front of and behind the entourage. Escorts must have direct communication with the transporter or vehicle being towed. Other road uses must be informed that an escort is in progress, including the destination and route.

The tow speed must be kept slow, with actual upper limit depending upon the make-up of the entourage, as well as, road and environmental conditions – always drive according to conditions.

If spotters or flagmen are used during retrieval, they must wear high visibility, reflective gear and be provided with appropriate communications. Inform all workers and operators that they are being used. Flagmen must use Red or Green Flags and have eye contact with driver/operator at all times.

Comprehensive hand-over arrangements should be established if retrieval will not be completed within the shift:

i. Outgoing workers are to report on progress, to ensure the work location is left in a safe state and to check that all barricades and signage are in place.

ii. Incoming workers must obtain handover details, check the work area and conduct prestart safety inspections on equipment.

Demobilization and Reporting

The recovery site is to be made safe at the end of the recovery process:

i. conduct housekeeping;

ii. remove and dispose of waste appropriately;

iii. clean up hydrocarbon spills;

iv. return recovery equipment & tools and report any change in their condition; and

v. take down barricades, signage etc.

The recovery team should also participate in a debriefing to discuss lessons learned, which may in turn stimulate a review of this PI to incorporate suggestions.

Complete recovery documentation and reporting.

General Safety Considerations

Each project site should ensure that equipment and tools are always available to assist recovery operations. Equipment and tools should be appropriate to the type of mobile equipment (light and Heavy) in use at the project. It must be kept in a fit-to-use state.

Examples of recovery tools and equipment to have available include:

i. Chains and tow slings;

ii. Lifting tackle;

iii. Hydraulic and mechanical jacks, winches, etc.;

iv. Lighting, barricades, tape, signage, etc.

Low Risk Light Vehicle Recovery – simple bogging

Inform Supervisor.

Conduct an Evaluation of situation.

Assemble tow vehicle and equipment – contact Workshop to discuss / obtain appropriate equipment.

Clear unnecessary people from the area or move back to a safe distance.

Use a suitable sized tow sling for recovery – check it is fit-for-purpose and safe-to-use.

Use an appropriate tow vehicle for recovery – check it is fit-for-purpose and safe-to-use.

Check the condition of the bogged vehicle – brakes, steering and engine.

Position tow vehicle on stable surface in front of (2-3m) LV being recovered

Attach sling / chain securely to manufacture tow points – contact Workshop if unsure of their location.

Move the towing vehicle forward slowly so that the webbing becomes tight and pull the light vehicle from the bog.

Remove chain / sling connect and return it.

Check retrieved vehicle for damage – report it, if any.

Washdown vehicles