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DRILLCORP GROUP OF COMPANIES

Competency Standards GEMCO H13 Drill Rig

TABLE OF CONTENTS

1. DEFINITION ................................................................................................................... 1

1.1. VARIABLES ........................................................................................................................... 1 1.2. RANGE STATEMENT ................................................................................................................ 1 1.3. CERTIFICATE ........................................................................................................................ 2

2. WORKPLACE PREPARATION AND RIGGING UP ............................................................. 2

2.1. PRE START CHECK ON LIGHT VEHICLES ....................................................................................... 3 2.2. COLLECT CONSUMABLES .......................................................................................................... 3 2.3. COMPLETE STOCKTAKE ............................................................................................................ 3 2.4. DRIVE TO SITE ...................................................................................................................... 3 2.5. ARRIVAL AT WORK SITE ........................................................................................................... 4 2.6. USE PERSONAL PROTECTIVE EQUIPMENT (PPE) ............................................................................ 4 2.7. DRILL SITE CHECK AND PREPARATION ......................................................................................... 4 2.8. RIG PRE-START CHECK ............................................................................................................ 5 2.9. START UP PROCEDURE ............................................................................................................ 7 2.10. JACKING THE RIG ................................................................................................................... 8 2.11. RAISING THE MAST ................................................................................................................ 8 2.12. SET UP CYCLONE/SPLITTER. ..................................................................................................... 8

3. COLLARING THE HOLE ................................................................................................... 9

3.1. TO ATTACH STARTING ROD .................................................................................................... 10 3.2. ATTACH 3 INCH AIR CORE BIT TO ROD ..................................................................................... 10 3.3. BREAK OUT AND REMOVE 3 INCH AIR CORE BIT FROM STARTING ROD .............................................. 10

4. MIXING A AND B FOAM ................................................................................................ 11

5. DRILLING ..................................................................................................................... 11

5.1. DRILL THE HOLE .................................................................................................................. 12 5.2. ADD A ROD WITH CLAM SHELL AND HOOK ................................................................................. 12 5.3. CHECKS DURING DRILLING ..................................................................................................... 12

6. END OF HOLE (E.O.H.) .................................................................................................. 13

6.1. FIT BLOW DOWN SUB ........................................................................................................... 14 6.2. CLEAR THE HOLE ................................................................................................................. 14 6.3. REMOVE BLOW DOWN SUB ..................................................................................................... 14 6.4. ATTACH AND USE BLOW BACK SUB ........................................................................................... 15

7. PULLING RODS ............................................................................................................ 16

7.1. PULL RODS AND UNLOAD RODS BY HAND ................................................................................... 16 7.2. TAKING A ROD OFF WITH A CLAM SHELL AND HOOK .................................................................. 16

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8. RIGGING DOWN ........................................................................................................... 17

8.1. DISCONNECT AND PACK UP CYCLONE ........................................................................................ 17 8.2. LOWER MAST AND RETRACT JACKS ........................................................................................... 18 8.3. SHUT DOWN AND PREPARE TO MOVE ........................................................................................ 18

9. TRAMMING CRAWLER TYPE RIGS BETWEEN HOLES & TRAMMING ONTO LOW LOADERS ...................................................................................................................... 18

9.1. COMPLETION OF HOLE. .......................................................................................................... 18 9.2. TRAMMING ONTO LOW LOADER. .............................................................................................. 19 9.3. TRAMMING RIG AT NIGHT ...................................................................................................... 19 9.4. END OF SHIFT ..................................................................................................................... 20

10. MAINTAIN EFFECTIVE WORKING RELATIONSHIPS ................................................ 20

10.1. PROVIDE QUALITY WORK FOR CLIENT ....................................................................................... 21 10.2. MAINTAIN PERSONAL HEALTH AND MANAGE STRESS ..................................................................... 21

11. COMMUNICATIONS .................................................................................................. 21

11.1. DAILY SHIFT REPORTING ....................................................................................................... 22 11.2. ORDERING PARTS AND CONSUMABLES ....................................................................................... 22 11.3. ACCIDENT/INCIDENT REPORT FORMS................................................................................. 22 11.4. DAILY DRILLING SHIFT REPORTS ............................................................................................ 22 11.5. FIELD MAINTENANCE BOOK .................................................................................................... 22

12. ISOLATED CAMP LIVING .......................................................................................... 23

12.1. SELECT SUITABLE CAMP SITE .................................................................................................. 23 12.2. SET UP SEA CONTAINER ACCOMODATION .................................................................................. 23 12.3. LOCATE POTABLE WATER ....................................................................................................... 23 12.4. ESTABLISH CAMP POWER SUPPLY ............................................................................................. 23 12.5. ENSURING GAS SUPPLIES ....................................................................................................... 23 12.6. MAINTAINING FRIDGE/FREEZERS ............................................................................................. 24 12.7. FOOD SUPPLIES ................................................................................................................... 24 12.8. CAMP CLEANLINESS .............................................................................................................. 24 12.9. SOCIAL ACTIVITIES .............................................................................................................. 24

13. APPENDIX ................................................................................................................ 25

13.1 SAVER SUBS, AIR SWIVEL AND HEAD INNER TUBE ........................................................................ 25 13.2 REMOVING AIR SWIVEL FROM HEAD .......................................................................................... 26 13.3 TO REFIT AIR SWIVEL ........................................................................................................... 26 13.4 TO RE FIT SAVER SUB ........................................................................................................... 27 13.5. BREAKING OUT HAMMER ........................................................................................................ 27 13.6 TO BREAK TOP SUB .............................................................................................................. 28

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1. DEFINITION The Gemco H13 Drill Rig is a self contained Rotary Drill mounted on a track mounted carrier (crawler type) and is primarily used by DrillCorp for mineral exploration. DrillCorp Rig 03 is fitted a 3306 Turbo charged Cat with a 320/750 compressor However not all DrillCorp H13 Rigs have this mechanical configuration with some exceptions: Rig 08 has a 6CTA 260 HP Cummins and no compressor. The motor only runs the hydraulic system and uses an Auxillary compressor unit. Rig 03 has a 6BTA 177 HP Cummins engine running the hydraulic system and a 3306 cat running the on board compressor. The 6BTA Cummins engine also powers the hydraulic system which in turn drives all the drill functions including the Rotary Head Drive, Pull Down, Pull Back Systems and the crawler tracks for moving the rig. The H13 Rig is specifically set up for using a 4‟ remet R/C rod string. The rig is capable of depths to 100m + depending on ground conditions. Rod handling is by winch and using a clam shell and hook. A Rig mounted rod bin holds 30 rods, and the extra rods are carried on an auxiliary support unit along with fuel, water, spare parts and equipment. A two (2) or three (3) man crew is required to run/operate the rig. It is possible to adapt the H13 Rig to R.A.B. (Rotary Air Blast) and R/C configuration using the same 3m x 3inch rods. 1.1. Variables

By the very nature of the Mineral Exploration Drilling Industry, and its contract based service, many variables are encountered throughout all aspects and levels of production. Therefore, the following is a list of contextual factors which may have to be considered in each case: 1.1.1. Client Requirements Location Sampling Drilling Technique 1.1.2. Drilling Rigs and Equipment Make, Model, Size, Age, Condition, and Maintenance Schedules Ratings and Capacity Suitability and Rig Layout 1.1.3. Ground Conditions

1.2. Range Statement

This range statement applies to the whole unit. Performance Objectives / Competency is to be demonstrated in the normal workplace environment(s) or equivalent. The Performance Objective for this unit will apply to all

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configurations of the H13 Drill Rigs Evidence of competency is to encompass the satisfactory application of:

The hierarchy of hazard control measures with elimination (eg; insulation of sources of thermal hazards), substitution, isolation and engineering control measures being selected before safe work practice(s) and personal protective equipment.

Current State/Territory OHS legislation, standards and codes of practice. Current Mines Regulations and Amended Acts. Workplace communication procedures. DrillCorp Standard Operating Procedures (SOP‟s). DrillCorp Competency Based Training and Assessment.

All attachments are operated in accordance with manufacturer‟s specifications.

1.3. Certificate

Drillers Certificate of Competency

Applicants applying for a certificate of competence shall be assessed throughout the course of their employment in accordance with DrillCorp Competency Based Training and Assessment guidelines.

2. WORKPLACE PREPARATION AND RIGGING UP Overview:

Prior to moving to the workplace, it is necessary to ensure all of the daily equipment, consumables, etc. Are collected for the days‟ shift, and before any vehicle is used, pre-start safety checks are performed to ensure the roadworthiness of the vehicle to reduce the likelihood of breakdown.

Upon arrival at the work-site all personal protective equipment (PPE) needs to be in place and site safety check(s) and preparation is performed to allow the site to be as safe as is reasonable practicable for the conditions.

To ensure the Rig is in good operating condition prior to commencing the shift, pre-start and correct start-up procedures need to be performed, and the Rig, cyclone and splitter are to be set up according to DrillCorp normal operational practices.

Aim: The aim of this section is to familiarise the trainee with the skills required to complete the tasks associated with workplace preparation and rigging-up, ensuring personal safety and the safety of others. Expected Outcome: Upon successful completion of the program, the trainee will be able to;

transfer correct normal operational practices to the workplace safely and efficiently,

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reduce injury risk and improve production. Outline: Pre Start Check. Collect Consumables. Complete Stocktake. Drive to Site. Arrival at work site. Use Personal Protective Equipment (PPE). Drill Site Check and Preparation. Rig Pre-Start Check. Start Up Procedure Jacking the Rig. Raising the Mast. Set Up Cyclone/Splitter.

2.1 Pre Start Check on Light Vehicles

2.1.1 Check engine oil, water, fuel, tyres (pressure - wear and tear) and wheel nuts. 2.1.1.1 All inspections are to be carried out according to the manufacturer‟s

specification and company procedures. 2.1.1.2 All components are checked to ensure they are free from damage,

leaks and obstructions which may limit the operational capability.

2.1.2 Check and clean windscreen and all lights, including amber flashing light. 2.1.3 Check tools as per list in toolbox, spare tyre(s), jack and wheel brace. 2.1.4 Check fire extinguisher (full or empty).

2.2 Collect Consumables

2.2.1 Collect consumables and or parts as required for the shift, from the Lay Down yard or Store.

2.2.2 Greases and Oils, etc.

2.3 Complete Stocktake

2.3.1 Complete a stocktake of the Lay down yard for re-ordering requirements. 2.3.2 List all supplies to enable re-ordering from the office within the country you

are currently working.

2.4 Drive to Site

2.4.1 Drive to drill site via main tracks 2.4.2 Drive to conditions 2.4.3 Ensure windows are wound up to prevent dirt/dust entering the cabin 2.4.4 Ensure access gates remain as found (if applicable)

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2.5 Arrival at work site

2.5.1 Park light vehicle up wind from the Rig 2.5.2 Park away from outside return hose 2.5.3 Ensure windows are wound up to prevent dirt/dust entering the cabin 2.5.4 Ensure hand brake applied

2.6 Use Personal Protective Equipment (PPE)

2.6.1 Ensure PPE is worn as required including

2.6.1.1 Hard hats 2.6.1.2 Hearing protection (ear plugs) 2.6.1.3 Steel capped safety boots 2.6.1.4 Safety glasses 2.6.1.5 Collared, sleeved shirts 2.6.1.6 Gloves and Dust Masks as directed

2.6.2 Take personal exposure resources and use as required 2.6.2.1 Sun cream 2.6.2.2 Water bottle 2.6.2.3 Store drinking water/esky in the shade

2.7 Drill Site Check and Preparation

2.7.1 Check site clearance and dimensions.

2.7.1.1 Check site safety. 2.7.1.2 Ensure vehicles and Rig are not compromised by parking

next to voids, open pits, old workings, etc. 2.7.1.3 Check for underground and overhead power lines, trees,

rocks, etc. on the site. 2.7.1.4 Check for good truck access. 2.7.1.5 Organise earthmoving equipment if required to ensure the

site area is cleared sufficiently. 2.7.1.6 Site to be as level as is practicable. 2.7.1.7 Check sample bag location.

2.7.2 Line up drill over hole as per Geologist‟s specifications. 2.7.2.1 Ensure correct location in relation to the Grid Peg. 2.7.2.2 Check hole angle, direction and depth from Geologist.

2.7.3 Position flagging tape or marking paint on ground for lining up Rig with position relative to the hole (unless already marked by Geologist). 2.7.3.1 Measure the distance from the centre line of the mast (ie;

Rod) to the drillers side of the Rig (Approx 1.2 to 1.3 metres).

2.7.3.2 From the fore-site, back-site and collar pegs, measure out and mark the corresponding (previously measured)

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distance and mark with flagging or paint. 2.7.3.3 This line must be seen from the drillers tramming console to

enable accurate positioning of the Rig.

2.7.4 Tram Rig along the tape edge or painted line and position the Rig correctly. 2.7.4.1 Measure the distance from rear jacks to collar location to enable

the Rig to be set up accurately on the hole. 2.7.4.2 For example, 1.3 metres from the rear jacks to the hole peg = an

angle of 60 degrees.

2.7.4.3 Disengage tramming hydraulic system. 2.7.4.4 Determine areas to park support trucks track mounted support

units for refuelling and water supply. 2.7.4.5 Allow access for auxiliary equipment or truck as required. 2.7.4.6 Ensure hoses reach the Rig from the auxiliary compressor truck. 2.7.4.7 Ensure the trucks or auxiliary track units are parked as level as

possible. 2.7.4.8 Parking brakes are to be applied. 2.7.4.9 If using trucks chock the wheels.

2.8 Rig pre-start check

2.8.1 Conduct visual inspection of Rig. 2.8.1.1 Check for engine and gear oil leaks. 2.8.1.2 Check for oil leaks on hoses or under carrier. 2.8.1.3 Check for oil leaks and general condition of all hydraulic hoses. 2.8.1.4 Check for water leaks.

2.8.2 All inspections are to be carried out according to the manufacturer‟s specification and company procedures.

2.8.3 All components are checked to ensure they are free from damage, leaks and obstructions which may limit the operational capability. 2.8.3.1 Check tyres (pressure - wear and tear) and wheel nuts on support

vehicles. 2.8.3.2 Check fire extinguisher(s) (full or empty) and has current dated

tag on fire extinguisher.

2.8.4 Delegate the following duties to the Offsider(s) ensuring correct Normal operational practices are followed. 2.8.2.1 Check condition of steps and hand holds (remove oil or mud build

ups).

2.8.5 Check Driller‟s console for cleanliness, broken gauges and loose objects under controls.

2.8.6 Check if any safety tags are attached.

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If a safety tag is attached, do not start rig and locate individual who affixed the tag to remove it if appropriate. If the person that placed the danger or out of service tag is not on site or available (he may be on break) then refer to Drillcorp Danger/Out of Service Tag Regulations.

2.8.7 Check Rig engine oil and top up as required 2.8.7.1 Locate dip stick and check oil level. 2.8.7.2 Locate filling point for engine oil and remove filler cap if

required. 2.8.7.3 Top up with correct oil (as per lubrication schedule) for

engine and replace filler cap.

2.8.8 Do not over fill or spill oil (if spillage occurs, clean up immediately). 2.8.9 Check water and top up as required

2.8.9.1 Locate radiator cap and (make sure radiator is not hot before removing radiator cap and check water level).

2.8.9.2 Remove filler cap if required. 2.8.9.3 Top up with clean water & coolant and replace filler cap.

2.8.10 Check hydraulic oil level. 2.8.10.1 Locate sight gauge and level mark. 2.8.10.2 Locate filling point for hydraulic tank and remove filler cap if

required. 2.8.10.3 Add correct oil (as per lubrication schedule) for hydraulic

system as necessary and replace filler cap. 2.8.10.4 Make sure the top of the oil drum is clean so no dirt can fall

into tank. 2.8.10.5 Do not over fill or spill oil (if spillage occurs, clean up

immediately).

2.8.11 Check compressor oil level. 2.8.11.1 Locate sight gauge and level mark. 2.8.11.2 Locate filling point for receiver tank. 2.8.11.3 If oil requires topping up, check that the air has been

drained from receiver tank prior to topping up. 2.8.11.4 Add correct oil (as per lubrication schedule) for compressor

as necessary and replace filler cap. 2.8.11.5 Do not over fill or spill oil (if spillage occurs, clean up

immediately).

2.8.12 Delegate Offsider(s) to grease components as required ensuring correct operational practices are followed: 2.8.12.1 Identify location of grease nipples as per lubrication

schedule. 2.8.12.2 Replace grease cartridge in hand grease gun as required and

grease appropriate areas.

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2.8.13 Delegate Offsider(s) to Fuel up Rig and ancillary plant as required ensuring correct normal operational practices are followed. 2.8.13.1 Position fuel truck next to rig to allow for re-fuelling. 2.8.13.2 Locate and remove filler cap. 2.8.13.3 Position filling nozzle into fuel tank ensuring the hose is not near

hot pipes, (exhaust, compressor, etc.) and fill tank via rotary pump.

2.8.13.4 Eliminate fuel spillage, not over fill or spill oil (if spillage occurs, clean up immediately).

2.8.13.5 Repeat during shift as required.

2.8.14 Complete final check. 2.8.14.1 Ensure Safety Hose Socks are serviceable and fastened correctly

to both anchor points. 2.8.14.2 Ensure pull down ropes or pull down chains are serviceable and

adjusted correctly. 2.8.14.3 Ensure clamps and or shackles are correctly rated and fastened

properly. 2.8.14.4 Check condition of sample hose and ensure sample hose safety

socks are fitted and anchored to both anchor points on deflector and on cyclone.

2.8.14.5 Ensure all guards are in place. 2.8.14.6 Check outside return hose is securely tied down and safety sock

is anchored to both anchor points on the stuffer box.

2.8.15 Delegate Offsider(s) to collect loose rags, rubbish, etc. from around the Rig and dispose of appropriately. 2.8.15.1 Ensure rubbish is not to be discarded. 2.8.15.2 Collect rubbish and place in old sample bag and place sample

bag in the back of the ute. 2.8.15.3 Dispose at mine-site dump at the end of shift on the way back to

camp. 2.8.15.4 Turn battery isolator switch to on position.

2.9 Start Up Procedure

2.9.1 Ensure P.P.E. is being used by all Crew members. 2.9.2 Check no person working on or near rig and the Crew is clear. 2.9.3 Ensure levers and air taps are centralised or in off position. 2.9.4 Turn ignition key on and check all warning lights. 2.9.5 Push start button and start engine. 2.9.6 Check gauges and warning lights, ensure all are operating correctly. 2.9.7 Complete final walk around inspection during warm-up looking for oil and

or water leaks, etc. The walk around inspection should take no more than five (5) minutes.

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2.10 Jacking the Rig

2.10.1 Familiarise self with jack levers and operation of same. 2.10.2 Ensure the Crew are in a safe location. 2.10.3 Set engine speed to high idle. 2.10.4 Place a wood block (pad piece) under the foot of each jack (ideal size

block of wood is 1m x 180mm x 180mm). 2.10.5 Run down jacks. 2.10.6 Using “Clinometer” level the Rig. 2.10.7 Check the location of jack feet ensuring they are:

2.10.7.1 Clear of old drill holes. 2.10.7.2 Clear of large unstable rocks. 2.10.7.3 Not too close to pit wall or cavity. 2.10.7.4 Sitting on firm solid ground.

2.11 Raising the Mast

2.11.1 Ensure there are no overhead power lines. 2.11.2 Familiarise self with mast raise lever and operation of same. 2.11.3 Select mast raise lever and raise mast to approximate angle required. 2.11.4 Check cables and hoses are free from snagging. 2.11.5 Set clinometer at desired hole angle (eg: 60) and place Clinometer on

head slide of mast.

Caution: Offsider to exercise caution when chaining the mast and should stand clear when setting the correct tension on the chain (dumping the mast).

2.11.6 Position mast at correct angle using clinometer bubble to determine the

angle. 2.11.7 With the mast just off the ground, secure a chain around the mast and

attach to the back of the rig. 2.11.8 Stand clear. Select mast dump lever and dump mast onto ground.

Check chain/rope tensions. 2.11.9 Re check the angle. 2.11.10 Delegate Offsider/s to place grease pot, hand tools, blow down and blow up subs close to hand.

2.12 Set Up Cyclone/Splitter.

2.12.1 Identify sample location and sampling procedures.

Discuss procedures with Geologist (or, as per Geologist instructions). 2.12.2 Delegate Offsider(s) to set up cyclone and splitter ensuring correct

normal operational practices are followed. 2.12.2.1 Undo locking pin and swing cyclone boom into position. 2.12.2.2 With sample hose unrolled fully and head at top of travel

and all twists are out of sample hose connect sample hose to the cyclone.

2.12.2.3 Connect the sample hose safety sock to the 2 separate anchor points on the cyclone

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2.12.2.4 Ensure area around cyclone is free from obstacles and hazards. 2.12.2.5 If you have a portable cyclone then if possible set up cyclone

downwind. 2.12.2.6 If water entry into the hole is possible. Build dam and dig a

trench downhill. 2.12.2.7 Ensure boss fittings are in serviceable condition. 2.12.2.8 Check wear on inside of fittings. 2.12.2.9 Attach sample hose to cyclone with two inch (2) boss fittings. 2.12.2.10 Ensure threads are clean and greased. 2.12.2.11 Use hammer to tighten fitting securely. 2.12.2.12 Attach Safety Hose Socks on the sample hose to the 2 separate

anchor points on the cyclone and the deflector. 2.12.2.13 Sample area to be cleared from obstacles (tripping hazards). 2.12.2.14 Check on bag size - Correct for cyclone. 2.12.2.15 Check on bag numbering and quantity.

2.12.3 Instruct offsider(s) in sampling requirements. 2.12.4 Ensure samples taken are laid out according to Geologist‟s specification.

3. COLLARING THE HOLE FOR AIR CORE DRILLING

Overview: The design of the air core system is such that no PVC collar is required. A mast mounted stuffing box and steel collar pipe and exhaust hose are fitted. To collar the hole, activate the dump mast and push the steel collar pipe into the ground. As little or no air\dust travels up the outside of the rods. The rig is ready to commence drilling. Aim: The aim of this section is to familiarise the trainee with the skills required to complete the tasks associated with collaring the hole prior to drilling, ensuring personal safety and the safety of others. Expected Outcome: Upon successful completion of the program, the trainee will be able to; transfer the correct normal operational practices to the workplace safely and efficiently, Reduce injury risk and improve production. Outline:

Attach Starting Rod Attach 4 inch Air Core Bit to Rod Break out and Remove 4 inch Air Core Bit from Starting Rod Mixing A and B Foam

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3.1 To Attach Starting Rod

3.1.1 A 3 Metre starting rod must be lifted onto slips table by hand or put on with clam shell and hook and held in position with box end facing head sub. Lower head sub into rod and rotate forward until thread is hand tight, then lower pin thread through slips and line up spanner flats with the bottom spanner to tighten head sub/starting rod thread.

3.2 Attach 4 Inch Air Core Bit to Rod

3.2.1 With 3m starting rod attached. 3.2.2 Locate serviceable air core bit and inner tube. 3.2.3 Delegate the Offsider to:

3.2.3.1 Check “O” rings. 3.2.3.2 Grease threads. 3.2.3.3 Screw complete bit (with inner tube) onto pin end of

starting rod by hand. 3.2.3.4 Remove slip inserts from table.

3.2.4 Select slow feed and lower bit through slips table and down through stuffing box rubbers.

3.3 Break Out and Remove 4 inch Air Core Bit from Starting Rod

3.3.1 Pull rods until starting rod is attached to head 3.3.2 Pull starting rod back 2m. 3.3.3 Delegate offsider to:

3.3.3.1 Remove slip inserts from table. 3.3.4 Idle back rig engine. 3.3.5 Use slow feed and pull back bit up through stuffing box rubbers

and into slips table.

Caution: Do not pull bit back above slips table. Bit must be inside table for breaking out.

3.3.5.1 Delegate Offsider to:

1. Locate serviceable 36 inch stilsons. 2. Adjust stilsons to suit 4 inch bit body. 3. Position (back-up) 36inch stilsons onto rod bin side of mast.

Caution: Ensure stilsons jaws are adjusted correctly- gap between inside of hook and bit should be 5mm (1/4 inch) and check that stilsons are positioned squarely onto bit.

3.3.6 Ensure offsider is clear of table area (behind the rod bin is considered

clear). 3.3.6.1 Select reverse rotation and break join between air core bit and

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3m starting rod. 3.3.6.2 Do not undo this join completely. 3.3.6.3 Delegate offsider to:

1. Remove 36inch stilsons 3.3.7 Select feed lever and pull back until bit is approximately 300m above table.

3.3.7.1 Delegate Offsider to: 1. Unscrew 4 inch air core bit by hand.

4. MIXING A AND B FOAM 4.1 When ground conditions dictate, A and B foam must be used to secure PVC

casing. ie; A diamond pre-collar or loose / broken ground at collar.

3.3.8 Wearing gloves, pour contents of (1 x A) tin and (1 x B) tin into plastic sample bag and roll bag top over several times to avoid spillage.

3.3.9 Shake contents until mixed. 3.3.10 Holding rolled edge of bag in one hand and just above opposite corner where mixture is located, and pour mixed foam around outside of PVC. 3.3.11 Do not wait too long before pouring as foam will not reach bottom of PVC.

Caution: The mixing and handling of A and B foam must be done in accordance with the

Material Safety Data Sheets (MSDS).

5. DRILLING

Overview:

Drilling in the mineral exploration industry is to provide quality samples to a given depth, determined by a Geologist to enable assaying to be performed on the samples provided. Aim: The aim of this section is to familiarise the trainee with the skills required to complete the tasks associated with drilling, ensuring personal safety and the safety of others. Expected Outcome: Upon successful completion of the program, the trainee will be able to; Transfer the correct normal operational practices to the workplace safely and efficiently, Reduce injury risk and improve production. Outline: Drill the Hole Add a rod with clam shell and hook

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Checks During Drilling

5.1 Drill the Hole

5.1.1 Check whereabouts of crew to ensure safety. 5.1.2 Open Drill engine throttle to full revs and turn the compressor to high /on. 5.1.3 Following appropriate normal operational practices, delegate Offsider to:

1. Have bags ready at cyclone. 5.1.4 Close air dump valve and open service air tap. Air should pass through

into cyclone and outside return hose. 5.1.5 Select and operate feed lever and lower rods to near ground level. 5.1.6 Select and engage forward rotation. 5.1.7 Select slow feed and lower rods into ground, sample should pass into

cyclone. 5.1.8 Regulate rotation speed and hold back (Bit weight) to suit conditions. 5.1.9 Lift off bottom momentarily at every meter mark to ensure quality

sampling. 5.1.10 Drill down to end of rod. 5.1.11 Pull back, so that spanner flats are at table level and will receive bottom

spanner. 5.1.12 Following appropriate normal operational practices, delegate Offsider to:

1. Take sample bag from cyclone as per Geologist‟s requirements. Ensure hole is clean before closing air tap and proceeding to add another rod.

5.1.13 Close main air tap and open air dump valve. 5.1.14 Stop rotation, aligning spanner “Flats” to receive bottom spanner. 5.1.15 Engage bottom spanner.

Ensure bottom spanner has fully engaged rod.

5.1.16 Check that all air has bled from rod string and engage reverse rotation. 5.1.17 Whilst rotating select slow feed and feed up in short runs to unscrew

threads evenly. 5.1.18 Stop rotation and grease thread on rod. 5.1.19 Engage fast feed when thread is unscrewed and lift head to near top

travel slowing down and using slow feed to top of travel. 5.1.20 Following appropriate normal operational practices, delegate Offsider to:

1. Remove endcap. 2. Visually check “O” rings and grease. 3. Grease threads at this point.

5.2 Add Rod with Clam Shell and Hook

5.2.1 Connect winch to clam shell.

5.2.2 Check wire sling from clam shell to hook is connected properly and in good condition.

5.2.3 Slide clam shell over the rod and place hook into rod ensuring hook is all the way in.

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5.2.4 Pull the clam shell up towards the top of the rod to tighten the sling. 5.2.5 Lift the winch up slowly. 5.2.6 Have one helper hold on to the hook and walk the rod around to the front of

the mast. 5.2.7 Line the rod up with the rotation head. 5.2.8 Lower the head sub into the box end of the rod. 5.2.9 Select forward rotation and rotate the head to screw up the thread. 5.2.10 Lower the winch pulling on the sling and clam shell until the clam shell is free

of the rod. 5.2.11 Set up clam shell and hook on the next rod so it is ready to go.

5.3 Checks during Drilling

5.3.1 Ensure air swivel and sample swivel are greased hourly. 5.3.2 Check for oil leaks on Rig. 5.3.3 Check for water leaks. 5.3.4 Check for leaks in head. 5.3.5 Check for creeping jacks. 5.3.6 Check hydraulic hoses for leaks. 5.3.7 Check sample hose does not fold over. 5.3.8 Check outside return. 5.3.9 Check sample quality and quantity. 5.3.10 Check fuel level in Rig.

6. END OF HOLE (E.O.H.) Overview: Once the pre-determined depth of a hole has been reached, end of hole (EOH) and pulling out procedures are performed to enable the rods to be pulled. To enable the rods to be pulled efficiently, the hole must be cleaned. Aim: The aim of this section is to familiarise the trainee with the process and procedures for blow down, and blow back (up) sub, and pulling the rods from the hole ensuring personal safety and the safety of others. Expected Outcome: Upon successful completion of the program, the trainee will be able to; transfer the correct normal operational practices to the workplace safely and efficiently, reduce injury risk and improve production. Outline: (Refer SOPD05 Cleaning of R/C Drill Holes) Fit Blow Down Sub. Clear The Hole.

Manuals….240409 14

Remove Blow Down Sub. Attach and Use Blow Back Sub. If rig is fitted with auto blow down unit Lift hammer off the bottom of the hole Activate Auto Blow Down Clear the hole.

NOTE: With the air core system, it is quite normal to drill a hole with little or no outside return. Once hole is drilled to depth it may not be possible to regain full outside return if at all. You may have to back ream a short distance to pull out of hole.

6.1 Fit Blow down Sub

6.1.1 On reaching required hole depth pull back off bottom slightly to allow last

of sample to pass into cyclone and sample bag. 6.1.2 Pull back to spanner flats and stop rotation so spanner flats will receive

bottom spanner. 6.1.3 Engage bottom spanner. 6.1.4 Close main air tap, open air dump valve and bleed air from line string. 6.1.5 Engage reverse rotation and undo head from rod. 6.1.6 Pull back to allow blow down sub to be fitted. 6.1.7 Check “O” rings in sub and rod and then grease the threads. 6.1.8 Screw blow down sub into rod by hand. 6.1.9 Lower head and screw head sub into blow down sub.

There is no need to over-tighten blow down sub with rotation

6.2 Clear the Hole

6.2.1 Disengage bottom spanner and slowly rotate rods forward. 6.2.2 Close air dump valve and open main air tap. 6.2.3 Air with cuttings and chips should flow freely from outside return hose. 6.2.4 Continue blowing down until outside return air is clear.

It may be necessary to work rod up and down to achieve full outside return air. For wet holes, follow the same procedure, but pour a quantity of drill foam down the blow down sub before screwing head into sub the foam will help lift mud and

cuttings to surface with the water.

6.3 Remove Blow down Sub

6.3.1 Once hole has been cleared, stop rotation and align spanner flats

with bottom spanner. 6.3.2 Engage bottom spanner, close main air tap and open air dump valve. 6.3.3 Engage reverse rotation to unscrew head from blow down sub. 6.3.4 Engage slow feed and feed up in short runs to undo the threads

evenly.

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It may be necessary to use breakout stilsons to remove blow down sub from rod.

6.3.5 Following appropriate normal operational practices, delegate Offsider to:

1. Remove blow down sub from rod.

6.4 Attach and Use Blow Back Sub

The Blow Back Sub is used to clear excess sample build-up or blockages in the sample line from rotary head through to the cyclone. Blockages can occur in; Head inner tube, Sample deflector, Sample hose, Cyclone.

Stilsons cannot be used to tighten or loosen any sub on a rod that is not anchored at both ends otherwise the rod will fling outside the mast taking anyone standing

in the way with the rod.

Attach the Blow Back Sub direct to rotation head or to drill rod attached on Head.

6.4.1 Delegate offsider to; 6.4.1.1 Locate and screw blow back sub to thread on R/C rotation head sub

or thread on R/C rod securely by hand. 6.4.2 Actuate rod centraliser. 6.4.3 Select slow feed and lower the rotation head or R/C rod with blow back sub

attached onto box end of rod in table. 6.4.4 Clear sample lines by ensuring that;

6.4.4.1 The sample hose is correctly attached to the cyclone and Safety Hose Sock is securely anchored to both anchor points in place.

6.4.4.2 Booster and auxiliary compressors are by-passed or disconnected prior to using blow back sub.

6.4.5 Close air dump. 6.4.6 Slowly open main air tap. 6.4.7 Monitor air pressure gauge. Do not allow air pressure to exceed 300psi. 6.4.8 Cuttings (sample build-up) should pass through sample hose and fall through

cyclone - blow until clear - turn air tap off. 6.4.9 If air pressure builds to 300psi, turn off main air tap. 6.4.10 Open air dump valve. 6.4.11 Determine location of blockage and clear obstruction manually. Do not strike

sample hose or boss clamp with hammer.

To Remove Blow Back Sub from 3m rod.

6.4.12 Select feed and raise the rotation head or R/C rod with blow back sub attached 300mm above table.

6.4.13 Delegate offsider to; Unscrew blow back sub from 3m rod by hand.

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7. PULLING RODS 7.1 Pull Rods and Unload Rods by Hand

7.1.1 Once hole has been cleared start “pulling rods” by rotating rods forward, engage feed up.

7.1.2 Pull back to join in rods and align spanner flats on lower rod with spanner bottom.

7.1.3 Stop rotation and engage bottom spanner.

Check gauges whilst pulling out to establish if hole is collaring on rods or hammer Kicks will be seen on gauge as “collars form”.

7.1.4 Open break-out stilsons. 7.1.5 Following appropriate normal operational practices, delegate Offsider to:

1. Position breakouts into rod squarely and with correct gap. 2. To keep clear once stilsons are in position.

7.1.6 Close / pull breakouts to “break” thread and remove breakouts. 7.1.7 Engage reverse rotation and slow feed up and undo threads.

Pin section must still be inside box end of lower rod but able to rotate freely.

7.1.8 Align upper rod spanner flats with 36” stilsons. 7.1.9 Select reverse rotation and with a short swift movement, break join at

head sub. 7.1.10 Delegate offsider to: Hold loose rod by hand firmly.

Gloves must be worn for rod handling

7.1.11 Select reverse rotation to undo join at head sub 7.1.12 Stop rotation and lift head clear of loose rod, delegate Offsider to

Offsider must be prepared to hold weight of the rod in position

1. Walk back away from rig whilst lowering rod 2. Ensure pin end of rod stays in box end of rod in table

7.1.13 Continue lowering rod until rod can be comfortably picked up and placed onto rod truck.

7.1.14 Once rod is clear, lower head to pick up next rod.

Caution: You must ensure good stance and use appropriate lifting techniques when handling drill rods.

7.2 Taking a Rod Off With the Clam Shell and Hook 7.2.1 Identify the clam break join at head as per 7.1.9

Manuals….240409 17

7.2.2 Lift rotation head up giving enough room to slide clam shell in and up the rod. 7.2.3 Once the clam shell is on the rod activate the winch up sliding the clam shell up

the rod and place the hook in the bottom of the rod. 7.2.4 Pull the winch up so the clam shell + sling + hook are all firmly in place. 7.2.5 Use reverse rotation to undo the head from the rod while holding the hook and

rod. 7.2.6 Have the helper walk the rod around the side of the rig putting the hook end in

the rod bin. 7.2.7 Lower the winch and rod down into the rod bin. 7.2.8 Remove shell and hook.

8. RIGGING DOWN

Overview: Rigging down is the process of packing up the Rig and equipment at the completion of the hole, and or in preparation of moving to the next site or hole. Aim: The aim of this section is to familiarise the trainee with the skills required to complete the tasks associated with rigging down, ensuring personal safety and the safety of others. Expected Outcome: Upon successful completion of the program, the trainee will be able to; transfer the correct normal operational practices to the workplace safely and

efficiently, reduce injury risk and improve production. Outline:

Disconnect and Pack Up Cyclone Lower Mast and Retract Jacks Shut Down and Prepare to Move End of Shift

8.1 Disconnect and Pack Up Cyclone

8.1.1 Undo outside return hose from tree / tyre, place in rod bin depending on length of move to next hole.

8.1.2 Remove safety hose sock from sample hose and undo sample hose from cyclone if required.

8.1.3 Remove side plate on cyclone, clean any clay, etc. from cyclone and replace and secure side plate to cyclone.

8.1.4 Remove cyclone chimney if fitted. 8.1.5 Swing cyclone boom into travel position and insert lock pin.

Manuals….240409 18

Place sample splitter and bags in ute, or carry to next hole.

8.2 Lower Mast and Retract Jacks

8.2.1 Select mast dump lever and dump mast up to correct position. 8.2.2 Wrap sample hose around / over table and into rod bin for lowering into

cradle. 8.2.3 Select mast tilt lever and lower mast into mast cradle. 8.2.4 Check on cables and hoses, etc. for snagging. 8.2.5 Select jack levers and retract all jacks.

8.3 Shut Down and Prepare to Move

8.3.1 Select tramming hydraulic system. 8.3.2 Place hole cap over hole. 8.3.3 Put blow back/down subs, grease and tools away for moving. 8.3.4 Remove steps and or ladders from decking. 8.3.5 Pick up rubbish around drill site and place in ute. 8.3.6 Perform pre-start up and start-up procedures on truck. 8.3.7 Walk around, check tyres, access to next hole, rubbish etc. 8.3.8 Clean truck/rig windows and mirrors. 8.3.9 Move mirrors in if require.

9. Tramming Crawler Type Rigs between Holes and Tramming onto Low

Loaders.

9.1 Completion of hole.

9.1.1 Lower drill mast onto cradle. 9.1.2 Pack equipment away for moving. 9.1.3 Raise rig jack. 9.1.4 Idle rig engine back. 9.1.5 Determine tramming/access route to new hole or low loader. 9.1.6 Driller to walk or travel to next hole in light vehicle. 9.1.7 Assess route conditions. Stay clear of power lines, water lines, loose boulders, pit walls and other machinery. 9.1.8 Once safety of access route has been determined, Driller can return to

the rig. 9.1.9 Safely tram to next hole. 9.1.10 Increase rig engine rev‟s to high. 9.1.11 Engage tramming hydraulic system. 9.1.12 Ensure drill crew are clear of rig and can be seen by the Driller at the

tramming control position. 9.1.13 One Offsider is to act as spotter for the blind side of the rig standing in a

position well clear of the rig and able to readily signal to the Driller. 9.1.14 Once drill crew are clear and spotter in position. 9.1.15 Engage tramming levers. 9.1.16 Both levers forward to move forward. 9.1.17 Both levers back to reverse.

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9.1.18 Disengage left or right lever accordingly to steer left or right. 9.1.19 Both levers in the neutral position to stop. Apply park brake when in location.

NOTE: - Tramming as with any operation of the rig is the responsibility of the Driller or Trainee Driller. Where the Trainee Driller is in charge of the rig. The Driller of Trainee Driller where instructed by a Supervisor, may instruct another person in the operation of the rig but only where that person has had sufficient experience on or about the rig. Under no circumstances is the Driller to relinquish control of his rig due to his own illness or injury other than to close the rig down or unless another person has had adequate and appropriate training on the rig or on other similar rigs and, or is otherwise approved as a Driller. Under no circumstances other than an emergency shut down is any non DrillCorp personnel to operate the rig without prior approval of DrillCorp Management. This includes tramming on and off low loaders or other trucks and ramps.

9.2 Tramming onto Low Loader.

9.2.1 Follow procedures for tramming to next hole. 9.2.2 Ensure spotter directs Driller onto low loader ramps squarely with tracks spaced evenly on ramps. 9.2.3 Select slow speed for tramming.

Only have ONE person guiding you on to the low loader.

Caution: - As rig trams over loading ramps and onto low loader deck, the rig may fall heavily onto low loader deck. Tram rig slowly and smoothly over the loading

ramps.

9.2.4 Once rig is positioned on the low loader, lower rig jacks to deck of loader. 9.2.5 Idle rig engine back for 3 minutes. 9.2.6 Switch rig engine off. 9.2.7 Chain rig down.

9.3 Tramming Rig at Night (Only in Extreme Emergency or Conducting Grade

Control at Night)

9.3.1 Position tramming spot lights front and back to ensure clear field of vision. 9.3.2 Follow procedures for tramming to next hole. 9.3.3 Stop rig and reposition tramming spot lights if conditions change e.g.

uphill/downhill. 9.3.4 Ensure tramming spot lights are serviceable and lenses clean. Replace

unserviceable lights immediately. 9.3.5 If lighting is inadequate for tramming, additional lighting will be required.

Use portable lighting tower where possible. 9.3.6 If portable lighting tower is impractical for any reason, advise drilling

Supervisor and alternative lighting methods will be employed. 9.3.7 Consult drilling Supervisor if safe tramming route cannot be determined or at

any time there is any uncertainty regarding any procedure.

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9.4 End of Shift

At the end of any given shift, depending on what status the hole is in. ie; still completing hole or completed hole. The driller is to idle back and ensure the Rig and equipment is washed down.

9.4.1 If hole is incomplete at end of shift, pull back at least 1 metres or above

water table if practical. 9.4.2 Shut air taps off and turn the compressor to low or off. 9.4.3 Idle back. 9.4.4 Connect water hoses from support truck to inlet on rig injection/water pump and open water tank tap. 9.4.5 Open and shut the appropriate taps on the Rig to ensure water is

directed through wash down hose. 9.4.6 Wear appropriate PPE. 9.4.7 Select and engage water pump lever. 9.4.8 Hose off Rig and equipment, cyclone and support units or trucks. 9.4.9 Upon completion turn off water pump and close all appropriate taps,

disconnect and roll up all hoses and pack away on truck. 9.4.10 Switch off or pull stop cable to shut down Rig. 9.4.11 Turn the ignition off and turn battery isolator switch to OFF position.

10. Maintain Effective Working Relationships

Overview:

Maintaining an effective working relationship is important to ensure continuity of work, health and hygiene and being preferred for new contracts.

Aim:

The aim of this section is to familiarise the trainee with the skills required to complete the tasks associated with effective working relationships, ensuring personal safety and the safety of others.

Expected Outcome:

Upon successful completion of the program, the trainee will be able to; transfer the correct normal operational practices to the workplace safely and

efficiently, reduce injury risk and improve production.

Outline:

Provide Quality Work for Client. Maintain Personal Health and Manage Stress.

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10.1 Provide Quality Work for Client

10.1.1 Provide consistent quality samples. 10.1.2 Communicate with Minerals Manager, Driller Supervisor(s), Training Officer(s), Clients, Geologists and peers in a courteous fashion. 10.1.3 Maintain appropriate standards of personal hygiene and demeanour. 10.1.4 Maintain Drill Rig in a clean and tidy condition.

10.2 Maintain Personal Health and Manage Stress

10.2.1 Identify risk factors associated with working in remote area environments.

10.2.2 Use strategies which promote and maintain health. 10.2.3 Become conversant with all record keeping requirements. 10.2.4 Use and implement available emergency procedures as and when

required.

11. COMMUNICATIONS Overview: In any job, good communication is essential. In the drilling minerals exploration industry it is necessary to communicate regularly and accurately as consumables, equipment daily metres, reports, etc need to be transmitted to the appropriate personnel to allow action to be taken, ie; Preparation of wages, urgent parts required and so on. Communication with the local DrillCorp office is to be performed on a daily basis. Aim: The aim of this section is to familiarise the trainee with the skills required to effect good communication, ensuring personal safety and the safety of others.

Expected Outcome: Upon successful completion of the program, the trainee will be able to; transfer the correct Normal operational practices to the workplace safely and efficiently. reduce injury risk and improve production. Outline: Daily Shift Reporting Ordering Parts and Consumables Incident and Worker‟s Compensation Forms Drilling Shift Reports (Plods) Field Maintenance Book

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11.1 Daily Shift Reporting

11.1.1 Demonstrate ability to use two way radio, correctly and clearly. 11.1.2 Demonstrate ability to use mobile phone correctly and clearly. 11.1.3 Demonstrate accurate note taking on daily drilling activities, charges,

and consumables. 11.1.4 Display accurate reporting of daily drilling activities, charges and

consumables to Group Operations Manager. 11.1.5 Indicate knowledge of emergency procedures for 2-way radio and

mobile phone.

11.2 Ordering Parts and Consumables

11.2.1 Demonstrate accurate stocktaking methods. 11.2.2 Indicate ability to order appropriate and sufficient consumables. 11.2.3 Identify part numbers (if fitted) or be able to explain part(s) required

to the local DrillCorp Office or Workshop.

11.3 Accident/Incident Report Forms

11.3.1 Show ability to fill in Accident/Incident forms accurately and clearly. 11.3.2 Ensure forms are sent to the DrillCorp Office as soon as possible to

assist in efficient processing.

11.4 Drilling Daily Shift Reports

11.4.1 Demonstrate accurate note taking on daily metreage, chargeable time, consumables and crew hours.

11.4.2 Demonstrate ability to fill in plods accurately and neatly. 11.4.3 Ensure pink copy of Daily Reports are sent to the office in the county

your currently working in on the 16th & 1st of every month.

11.5 Field Maintenance Book

11.5.1 Indicate the ability to assess mechanical problems and record problems in maintenance book.

11.5.2 Refer to DrillCorp Workshop for action to be taken. 11.5.3 Identify and record all required information as listed in daily

maintenance schedule. 11.5.4 Engine hours recorded at start of every shift and oil consumption used

in rig engine.

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12. Isolated Camp Living Elements of Basic Competence

12.1 Select Suitable Camp Site

Select a suitable camp site not too far from work area. 12.1.1 Select a suitable camp site with adequate shade if possible. 12.1.2 Set camp upwind if close to roadway or dusty area. 12.1.3 Take hillsides and sloping areas into consideration re: water run-off

during rain, flooding creeks, etc.

12.2 Set Up Sea Container Accommodation

12.2.1 Set up sea container utilising jacks to make level. 12.2.2 Set up shower correctly 12.2.3 Remove debris, rocks, and branches from camp area.

12.3 Locate Potable Water

12.3.1 Locate source of “potable” water from; town, farm or bore. Do not drink

any local water. Only drink bottled water 12.3.2 Set bore hole pump (if required) utilising correct procedure for running

submersible pump and equipment. 12.3.3 Correctly prime and bleed the water pump and change filter as

required. 12.3.4 Position camp water tank level, located for water access. 12.3.5 Position water hose correctly and connect to pump inlet correctly. 12.3.6 Maintain adequate water supply and re-fill tank as required. . 12.3.7 Do not drink any local water. Only drink bottled water 12.3.8 Position washing machine close to power supply, close to water supply. 12.3.9 Connect water supply. 12.3.10 Provide water run off facility.

12.4 Establish Camp Power Supply

12.4.1 Locate diesel generator downwind if possible, distance from camp

dependent on power lead length. 12.4.2 Clear area around generator set to reduce possibility fire hazard. 12.4.3 Provide adequate fuel storage or refuelling supply. 12.4.4 Keep correct oils on hand - service kits on hand. 12.4.5 Ensure familiarity with generator set operating procedures and

servicing requirements. 12.5 Ensuring Gas Supplies

12.5.1 Ensure adequate supply from gas bottles maintaining correct SOP‟s.

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12.5.2 Ensure gas regulator and fittings must be in serviceable condition. 12.5.3 When turning gas on/off, check for leaks.

DO NOT store bottles inside accommodation unit.

12.5.4 Demonstrate familiarisation with oven operation.

12.6 Maintaining Fridge/Freezers

12.6.1 Maintain fridges/freezers in Good working Order. 12.6.2 Clean fridge/freezer regularly to maintain hygiene. 12.6.3 Load fridges/freezers, packing in accommodation unit or vehicle for

travel.

12.7 Food Supplies

12.7.1 Maintain adequate food supplies by liaising with the Driller/supervisor. 12.7.2 Ensure over/ under ordering is minimised by accurate stock taking. 12.7.3 Check shelf life expiry dates and storage requirement. 12.7.4 Defrosting meat, etc appropriately considering summer/winter meat,

defrosting, flies - heat/ various meat types. 12.7.5 Maintain personal cleanliness by showering prior to cooking and

ensure all utensils clean. 12.7.6 Prepare well balanced/ nutritious meals. 12.7.7 Maintain a clean and tidy kitchen and ensure dishes and kitchen,

floors and tables are cleaned daily. 12.7.8 Prepare esky for lunches daily. 12.7.9 Prepare ice for next day‟s drinking water (if applicable).

12.8 Camp Cleanliness

12.8.1 Establish and utilise rubbish bins around the camp. 12.8.2 Locate rubbish tip and make regular tip runs to help keep wildlife out

of bins. 12.8.3 Operate washing machines correctly ensuring no overloading. 12.8.4 Pre-rinse clothes in drum prior to washing. 12.8.5 Ensure adequate care and transport of machine. 12.8.6 Sweep accommodation unit floors, keep personal items neat and

maintain general tidiness. 12.8.7 Keep personal dirty clothes washed or in bag. 12.8.8 Connect shower hoses correctly, maintain operation of shower and

ensure water run off adequate. 12.8.9 Shower before Dinner to maintain personal hygiene.

12.9 Social Activities

12.9.1 Know your limitations in relation to alcohol intake and maintain civil

behaviour.

Manuals….240409 25

12.9.2 Ensure you are fit for work next day. 12.9.3 Respect individual(s) needs, let people be alone after hours as

personalities vary. 12.9.4 Refer to Company SOP‟s re: vehicle use after hours, travelling to town

or the pub and phone calls home.

13. APPENDIX

13.1 Saver Subs, Air Swivels and Head Inner Tube

13.1.1 It is necessary to change out saver subs and head inner tubes as these items are subject to wear.

13.1.2 Air swivels need maintenance in the form of bearing and “O” ring replacement as required.

13.1.3 To Remove/Replace Saver Sub. 13.1.4 Unscrew head from rod. Do not lift pin of saver sub out of rod box end.

Threads must be unscrewed. 13.1.5 Rotate head slowly, forward or reverse, hit saver sub on box end with

hammer. This action will assist in loosening thread, it will be necessary to continue hitting saver sub in this fashion for a few minutes.

13.1.6 Position 48” stilsons onto saver sub box end.

Stillsons must be positioned correctly - (90 degrees to saver sub) and (backed up) to Drillers side of mast. This is to prevent saver sub turning when reverse head rotation is engaged.

13.1.7 Make sure all crew are clear from platform area, and check 48” stilsons again for position.

13.1.8 Select and engage full reverse rotation to undo saver sub/air swivel thread. If saver sub will not “break”, repeat this method several times.

13.1.9 If saver sub refuses repeated attempts to break, it will be necessary to remove 48” stilsons and position them onto lower pin of air swivel. 48” stilsons must be “backed up” onto rod bin side of mast.

13.1.10 60”break out” stilsons must be reversed by removing hinge pin and turning stilsons over 180 degrees - replace hinge pin. This allows “break outs” to work in reverse.

13.1.11 With 48” stilson correctly positioned and all crew clear of the platform area. Engage “breakouts” to undo saver sub. Again, several attempts at this procedure may be required to break out thread.

13.1.12 If repeated attempts continue to fail it will be necessary to heat saver sub with oxy/acetylene torch.

Correct safety goggles to be used in this procedure.

13.1.13 When heating saver sub it is not necessary to get sub red hot. An even heat around the sub should be sufficient.

13.1.14 Rapid cooling of saver sub with water will provide assistance to break out should several attempts with heat alone fail.

13.1.15 Use caution removing hot saver sub.

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13.1.16 Replacing Head Inner Tube; Head inner tube can be replaced only once saver sub has been removed. This design allows head inner tube to be pulled down from head, replaced, and pushed back into head and on replacing saver sub, held securely in position.

13.2 Removing Air Swivel from Head;

13.2.1 Undo all air hoses/ plumbing from swivel. 13.2.2 Carry out procedure for saver sub removal, but do not remove saver

sub from air swivel pin. Saver sub must be still screwed onto air swivel pin thread.

13.2.3 Saver sub pin to be located into box end of rod in slips table. This procedure prevents excessive or sudden head movement during breakout process.

13.2.4 With sub saver pin sitting, but not screwed into box end of rod. Position 48” stilsons on lower pin of air swivel located between air swivel body and saver sub.

13.2.5 Check that stilsons are positioned correctly (90 degrees to sub) and are „backed-up‟, onto Drillers side of mast. This will prevent air swivel turning when head rotation is reversed.

13.2.6 With stilsons positioned correctly, saver sub pin sitting in box end of rod and crew clear of platform area.

13.2.7 Engage full reverse rotation to break air swivel from the pin to pin, sub located between air swivel and head spindle.

13.2.8 If air swivel thread refuses to break. Remove 48” stilsons and strike air swivel box end with hammer.

13.2.9 Replace 48” stilsons correctly on lower pin end of air swivel and back up to Drillers side of mast.

13.2.10 Repeat break out procedure. 13.2.11 If swivel refuses to break using this method. Remove 48” stilsons

and re-position stilsons onto pin to pin sub located between air swivel and head spindle. Position 48” stilsons correctly and back up onto rod bin side of mast.

13.2.12 60” break-out stilsons must be reversed by removing hinge pin and turning 60” stilsons over 180 degrees. Replace hinge pin, this allows breakouts to work in reverse.

13.2.13 Position 60” breakouts onto lower pin of air swivel.

Ensure breakouts are placed correctly.

13.2.14 With crew clear of platform area and all stilsons positioned correctly engage breakouts to break out air swivel.

13.2.15 Several attempts may be required to “break” threads.

13.3 To Refit Air Swivel

13.3.1 To ensure all threads are clean and greased. 13.3.2 Locate air swivel onto slips table with pin down and hold in upright

position.

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13.3.3 Use caution: Do not place fingers under pin thread. 13.3.4 Slowly lower head so that the pin to pin sub enters box end (top) of air

swivel. 13.3.5 Engage forward rotation to screw air swivel onto pin to pin sub. 13.3.6 Tighten threads as far as possible while holding air swivel by hand only. 13.3.7 To tighten air swivel securely. Ensure pin thread of air swivel is sitting in

(but not screwed to) box end of rod or air swivel pin thread is sitting in slips table. This will stop excessive head movement when tightening air swivel.

13.3.8 Position 48” stilsons correctly on pin end section (not the actual threads) and back up to rod bin side of mast.

13.3.9 With crew clear of platform area, stilson positioned correctly, and pin thread located in slips table or rod box end, engage forward rotation to screw home air swivel threads.

13.3.10 Remove 48” stilsons. 13.3.11 Refit all air fittings and hoses. 13.3.12 Once air swivel has been „broken out‟ remove 60“ stilsons, from air swivel. 13.3.13 Change 60” stilsons back to regular position. 13.3.14 Remove 48” stilsons. 13.3.15 Position 48” stilsons on pin end of air swivel and back-up stilsons onto

Drillers side of mast. 13.3.16 With crew clear of platform area, stilsons adjusted and positioned

correctly. 13.3.17 Engage reverse rotation slowly to unscrew swivel thread completely. 13.3.18 Remove 48” stilsons. 13.3.19 Air swivel can be removed for maintenance or replacement.

13.4 To Re Fit Saver Sub

13.4.1 Air swivel should already be attached to head. Air fittings and pipes

attached. 13.4.2 Ensure all threads are clean and greased. 13.4.3 Insert new or replace head inner tube. 13.4.4 By hand, screw saver sub onto air swivel pin thread. 13.4.5 Position 48” stilsons onto box end or saver sub. 13.4.6 Ensure stilsons are correctly adjusted and backed up onto rod bin side of

mast. 13.4.7 With the crew clear from platform area. Engage forward rotation to screw

up saver sub. Increase rotation pressure to maximum to ensure saver sub is tight.

13.4.8 Once saver sub is tight. Remove 48” stilsons. Grease pin end of saver sub. Head assembly is now ready to continue drilling.

13.5 Breaking out Hammer

13.5.1 Down hole hammers require maintenance and replacement of internal

parts at regular intervals. 13.5.2 To remove internal parts the bit/drive sub/ shroud assembly and the “top

sub” must be “broken out”. Bit break out as per the relevant manual.

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13.6 To Break Top Sub

13.6.1 Having removed bit assembly open table retract, remove bit basket. 13.6.2 Lower hammer through slips table until breakouts are level with top

sub of hammer. Allow room for 48” stilsons, below join. 13.6.3 Close table retract onto hammer. 13.6.4 Position 48” stilson onto hammer case below top sub join and back up

stilsons onto driller‟s side of mast. 13.6.5 Ensure stilsons are fitted correctly. 13.6.6 Open breakouts. 13.6.7 Position breakouts onto top sub. 13.6.8 Ensure breakouts fitted correctly. 13.6.9 Crew to clear platform area. 13.6.10 Close breakouts to break top sub. 13.6.11 Once top sub has “broken”, remove breakouts and rotate in reverse 1 or 2 revolutions to undo thread. 13.6.12 Remove 48” stilsons. 13.6.13 To break starter rod from top sub, lower hammer and rotate forward

until spanner flats on top sub align, with bottom spanner. 13.6.14 Engage bottom spanner. 13.6.15 Open breakouts. 13.6.16 Position breakouts on starter rod. Ensure breakouts are fitted

correctly. 13.6.17 Crew to be clear from platform area. 13.6.18 Close breakouts to break rod/ top sub join. 13.6.19 Once rod/ top sub join has broken. 13.6.20 Remove breakouts. 13.6.21 Engage rod centraliser and hold down. 13.6.22 Engage reverse rotation to unscrew rod from top sub. Use slow feed

up to undo threads unevenly. 13.6.23 Pull starter rod up to clear top sub. 13.6.24 Release rod centraliser. 13.6.25 Remove locking pin and open slips table. 13.6.26 Hammer can be lifted out from slips and bottom spanner for maintenance.