Product Overview

Summary: This Automated Drilling System Safe Operating Procedure provides a clear, step‑by‑step framework for safely planning, setting up and operating automated drilling equipment in Australian workplaces. It helps organisations control high‑risk mechanical and energy hazards while improving consistency, productivity and WHS compliance across drilling operations.

Automated drilling systems significantly reduce manual handling and operator exposure at the drill face, but they also introduce complex mechanical, electrical and software‑related risks that must be carefully controlled. This Safe Operating Procedure sets out a practical, end‑to‑end method for managing those risks – from pre‑start inspections and isolation of energy sources through to programming, test runs, live operation, maintenance and shutdown. It is written specifically for Australian conditions and aligns with WHS duties for high‑risk plant, remote operation and contractor management.

By implementing this SOP, organisations can standardise how automated drills are used across sites and shifts, ensuring that operators, maintainers and supervisors follow the same safe sequence every time. The document addresses real‑world issues such as guarding and exclusion zones, failure of sensors and interlocks, unexpected movement during automatic cycles, integration with fleet management systems, and clear communication between the control room and field personnel. It helps businesses demonstrate due diligence, reduce downtime from equipment damage or misalignment, and provide defensible evidence of safe work procedures during audits, client pre‑qualifications or regulator investigations.

Key Benefits

• Ensure consistent, safe operation of automated drilling systems across all sites and shifts.
• Reduce the likelihood of crush, entanglement and struck‑by incidents associated with moving plant.
• Demonstrate compliance with Australian WHS legislation and plant safety requirements for high‑risk equipment.
• Streamline onboarding and competency assessment for operators, maintainers and contractors working with automated drills.
• Minimise unplanned downtime and costly repairs caused by incorrect setup, programming or shutdown procedures.

Who is this for?

• Drilling Supervisors
• Rig Managers
• Mining and Quarrying Supervisors
• Automation and Controls Engineers
• Maintenance Supervisors
• WHS Managers and Advisors
• Project Engineers
• Site Managers
• Production Managers in Mining and Resources
• Training and Competency Coordinators

Hazards Addressed

• Contact with moving parts leading to crush or entanglement injuries
• Unexpected movement of the drill rig or boom during automated cycles
• Struck‑by hazards from rotating drill strings, rods and tooling
• Failure or bypassing of guards, interlocks and proximity sensors
• High‑pressure hydraulic, pneumatic or coolant fluid release
• Electric shock or arc flash from electrical and control systems
• Noise and vibration exposure from drilling operations
• Dust and respirable crystalline silica exposure from drilling into rock or concrete
• Ground instability, fall of ground or hole collapse around the drilling area
• Collision risks with other mobile plant in shared work zones
• Manual handling injuries during rod handling, bit changes and maintenance
• Ergonomic strain for operators using control consoles or remote control devices
• Fire risk from overheating components, electrical faults or hydraulic oil leaks
• Cyber‑physical risks such as incorrect software updates or unauthorised parameter changes affecting safe operation

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Definitions and Abbreviations
• 3.0 Roles and Responsibilities (Operators, Supervisors, Maintenance, Control Room)
• 4.0 Description of the Automated Drilling System and Safety Features
• 5.0 Competency, Training and Authorisation Requirements
• 6.0 Required Personal Protective Equipment (PPE)
• 7.0 Pre‑Start Inspections and Safety Checks
• 8.0 Site Preparation, Ground Assessment and Exclusion Zones
• 9.0 Lockout/Tagout and Isolation of Energy Sources
• 10.0 Programming, Calibration and Test Run Procedures
• 11.0 Normal Operating Procedure – Automated and Manual Modes
• 12.0 Interaction with Other Mobile Plant and Traffic Management Controls
• 13.0 Dust, Noise and Vibration Control Measures
• 14.0 Rod Handling, Bit Change and Tooling Procedures
• 15.0 Maintenance, Fault‑Finding and Reset Procedures
• 16.0 Managing Control System Alarms, Interlocks and Overrides
• 17.0 Emergency Stop, Emergency Response and Incident Reporting
• 18.0 Housekeeping, Shutdown and Securing the Drill
• 19.0 Recordkeeping, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory variants)
• Work Health and Safety Regulation 2011 (particularly provisions for plant and high‑risk work)
• Safe Work Australia – Code of Practice: Managing the Risk of Plant in the Workplace
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• Safe Work Australia – Code of Practice: Managing Noise and Preventing Hearing Loss at Work
• Model Code of Practice: Excavation Work (relevant to ground stability and drilling activities)
• AS/NZS 4024 series: Safety of machinery
• AS 4240: Remote controls for mining equipment (where remote or automated operation is used)
• AS/NZS 3000: Electrical installations (Wiring Rules)
• AS/NZS 4801: Occupational health and safety management systems (superseded but still commonly referenced)
• ISO 45001: Occupational health and safety management systems (where adopted by the organisation)