mining engineering: Fatal Risk Control Protocols

INTRODUCTION

BACKGROUND

A review of our past fatalities and significant incidents have identified a series of key fatal risks to our people – risks that require the development of sound practices to eliminate fatalities and incidents that could, in slightly different circumstances, cause fatalities. These Fatal Risk Control Protocols, developed through workgroups made up of individuals from across with extensive experience in operations, establish minimum performance expectations for managing these risk areas at leading practice levels.

The existence of these Protocols does not presume coverage of all risks areas faced by our operations (including some which have caused multiple fatalities). These other risk areas are addressed through the risk management process that is a key element of the HSEC Management Standards.

CONTEXT

These Protocols should be read and used in conjunction with the HSEC Policy and HSEC Management Standards. The HSEC management system, as shown below, is hierarchical where documents and systems must meet and support the requirements of those of higher levels. These Protocols are mandatory to all controlled sites and operations.

APPLICATION

These Protocols apply at all controlled sites and controlled activities, and to all employees, contractors and visitors when involved in controlled activities.

REQUIREMENTS

The mandatory requirements of these Protocols are signified by the use of the word “shall”.

The word “should” indicates that the primary intent is to comply with the full requirements as if they were mandatory.

However, there will be circumstances where local conditions may demonstrate that the requirement is either not applicable or an alternative approach is necessary. In cases where “should” has been used in a requirement, variation can only be considered as compliance if the most Senior Manager of the operation approves it based on an evaluation of the risk. The risk management approach adopted must be consistent with the Management Guideline and follow the Hierarchy of Controls as shown below.

HIERARCHY OF CONTROLS should be applied in the following order:

ELIMINATE: The complete elimination of the hazard

SUBSTITUTE: Replacing the material or process with a less hazardous one

REDESIGN: Redesign the equipment or work processes

SEPARATE: Isolating the hazard by guarding or enclosing it

ADMINISTRATE: Providing control such as training, procedures etc.

PERSONAL PROTECTIVE EQUIPMENT: Use appropriate and properly fitted PPE where other controls are not practical.

It is recognised that sound (and formalised) risk management principles are still required (i.e. beyond simple compliance with a mandatory Protocol) to identify, quantify, control and reduce the likelihood of incidents through the investigation, assessment and understanding of hazards associated with the activities covered by these Protocols.owns and operates a diverse range of businesses in different countries and cultures around the world, with varying legal frameworks. When applying procedures and practices to meet the needs of these Protocols, the relevant legislation must be complied with.

The nature of hazards and extent of risk may be significantly influenced by changes implemented to operations, processes, equipment, systems, services and people. This requires procedures to assess the effect of these changes and the associated risks. As with any formal risk management process, appropriate change management processes shall be in place at all operations.

APPROVAL FOR ALTERNATIVE CONTROLS

In unique circumstances where the specific requirements of a Fatal Risk Control Protocol cannot be fully achieved, approval for alternative control measures shall be obtained by providing a comprehensive and documented risk-based management control plan, containing the following:

- Details of the Fatal Risk Control Protocol conformance gap/s

- Alternative controls to be implemented

- Time frame and associated conditions towards achieving compliance

- Assigned single point accountability and

- Sign off by the “one up manager” to the most senior manager of the site/operation.

STRUCTURE OF THE PROTOCOLS

The requirements of these Protocols are classified into the three broad focus areas:

A. Plant and Equipment Requirements

B. Procedural Requirements

C. People Requirements

These three areas cover the essential controls that are to be in place in order to comprehensively manage these risk categories. The diagram below demonstrates how this approach, combined with committed leadership and supported by our Charter, HSEC Policy, and Future State is designed to deliver our goal of Zero Harm.

The Road to Zero Harm

LIGHT VEHICLES

INTENT

To eliminate or minimise the risk of fatalities, injuries and incidents arising from the use of light vehicles in surface operations.

APPLICATION

This Protocol applies to all light vehicles used for work related activity that can be road registered, and can be used for transporting people and light loads. Examples of light vehicles covered by this Protocol are passenger cars, four wheel drives (including all wheel drives), sports utility vehicles (SUVs), pick-ups (utilities, bakkies), mini buses, etc. This Protocol applies to all controlled sites and activities, and to all employees, contractors and visitors when involved in controlled activities.

REASON FOR INCLUSION

Light vehicles have been involved in a significant proportion of our fatal and high potential incidents. Identified causes and contributing factors include:

- inappropriate speed for conditions

- driver fatigue

- vehicle stability

- driver distraction

- vehicle condition (tyres, brakes, etc.)

- alcohol and drugs

- poor visibility

- lack of vehicle separation from other mobile equipment, plant and pedestrians

- risk taking behaviour

- driver experience / competency.

REQUIREMENTS

The mandatory requirements of these Protocols are signified by the use of the word “shall”.

The word “should” indicates that the primary intent is to comply with the full requirements as if they were mandatory.

However, there will be circumstances where local conditions may demonstrate that the requirement is either not applicable or an alternative approach is necessary. In cases where “should” has been used in a requirement, variation can only be considered as compliance if the most Senior Manager of the operation approves it based on an evaluation of the risk. The risk management approach adopted must be consistent with the HSEC Risk Management Guideline and follow the Hierarchy of Controls.

The requirements of this Protocol are as follows:

A PLANT AND EQUIPMENT REQUIREMENTS

1. Light vehicles shall have the following minimum safety features:

- seat belts for all occupants

- roll-over protection for all four wheel drive vehicles

- cargo barriers and load restraints for all vehicles designed for carrying loads (other than passengers), or that are unable to have cargo separated from the vehicle’s occupant carrying space

- driver-side air bag.

2. Light vehicles that interact with heavy mobile equipment and/or plant shall have:

- means that enables positive communication to be made with that equipment and/or plant

- high visibility flag e.g. a whip flag or buggy whip

- flashing, revolving or strobe light.

3. Light vehicles shall not have seating that is side mounted.

4. Light vehicles operating on site should be fitted with signage allowing for easy and positive vehicle identification from a reasonable distance.

5. Light vehicles should have:

- high visibility colour

- reflective taping

- first aid kit

- emergency roadside triangles or beacons (three of either)

- survival or emergency equipment suitable for the operating environment.

6. A change management process shall accompany all vehicle modifications, including the attachment of any equipment.

Examples of changes or modifications may include, but not be limited to:

- any change or modification made to the overall vehicle body structure or design

- any change or modification made to the original manufacturer fitted type of tyres or wheels

- any change or modification made to the vehicle suspension system

- any change or modification made to the vehicle’s mechanical system

- any change or modification that may adversely alter the vehicle’s centre of gravity

- any change that alters the vehicle’s load carrying capacity

- any change that may affect the vehicle’s crash-worthiness or the effective operation of any vehicle feature e.g. the fitment of a “bull bar”.

B. PROCEDURAL REQUIREMENTS

7. Vehicle selection shall be based on risk assessment taking account of tasks, application, environment and roll over and crash worthiness ratings.

8. A formal inspection and preventative maintenance system shall be in place to ensure that vehicles are maintained in a safe and roadworthy condition, and as a minimum serviced in line with the vehicle manufacturer’s service schedule. Inspection and maintenance shall be undertaken on the following critical items:

- wheels and tyres

- steering, suspension and braking system

- seats and seat belts

- lamps, indicators and reflectors

- windscreen and windows including windscreen wipers and washers

- the vehicle structure itself

- other safety related items on the body, chassis or engine, including instrumentation.

9. Seat belts shall be used in all cases by all occupants.

10. A pre-operation vehicle safety check and familiarisation system shall be in place and used by the driver.

11. Systems shall be in place to ensure that risks associated with vehicle journeys are managed and controlled. The systems shall include, but not limited, to:

- journey management plans in place prior to commencement of new or changed travel activities

- identification and monitoring of the risks associated with the number of journeys, routes, intersections, etc. to ensure that the overall exposure is reduced to as low as reasonably practicable

- assessment and communication of changed environmental and road conditions at the time of travel

- outline of actions required in the event of an emergency e.g. collision or break down

- provision to manage driver fatigue.

12. Light vehicle running lights (low beam headlamps) shall be left on at all times when the vehicle is in operation.

13. Mobile phones, whether hands free or not, shall only be used by the driver of a vehicle whilst the vehicle is stationary and in a safe location.

14. Controls shall be in place to ensure the safety of people working on road-ways, including working on unexpected vehicle breakdowns.

15. A site-based review of pedestrian interaction, road design and layouts (including entrance and exit points, intersections and other potential points of interaction between light vehicles and other mobile equipment), shall be conducted and updated when changes to layouts are required. Where possible, traffic segregation should be used to separate pedestrians, light vehicles and other mobile equipment.

16. A site-based traffic management plan shall be in place including, but not limited to the following:

- setting of appropriate speed limits for vehicle types, road surfaces and environmental conditions

- overtaking protocol

- procedures for light vehicles entering hazardous or restricted areas

- clear communication protocols

- standards for safe following distances based on operational circumstances, environmental conditions and near sight (blind spot) limitations of other mobile equipment

- installation and maintenance of road traffic control signs as appropriate to the work site

- parking procedures e.g. safe parking distances / locations and required barriers from heavy mobile equipment and pedestrians.

C. PEOPLE REQUIREMENTS

17. All employees, contractors and visitors shall be inducted in appropriate road safety and site vehicle hazards.

18. A permit or certification system shall be in place to ensure drivers are competent to operate the type of vehicle/s in its intended environment, whether that be internal or external to a site.

19. A system shall be in place to verify that drivers of vehicles have a valid and appropriate level public road driver’s licence prior to being allowed to operate a vehicle off site.

20. A system shall be in place to ensure that drivers undertake adequate training to ensure that the vehicle intended to be operated or driven can be operated or driven safely. As a minimum training should include:

- behavioural based defensive driving principles

- vehicle familiarisation, taking into account the vehicles handling dynamics and various features

- loading and restraining principles where the vehicle intended to be operated is designed for carrying cargo loads

- education and awareness of driving and travel risks that may be encountered within the environment where the vehicle may be operated or driven

- emergency crash and breakdown procedures

- basic mechanical principles including tyre changing and how to adequately perform a pre-operation check.

21. A system shall be in place to ensure any person operating any equipment associated with a light vehicle (e.g. vehicle-mounted cranes and winches) is suitably trained and accredited.

22. Behaviour based observations shall include the operation of light vehicles. Any need for additional specific retraining shall incorporate the results of these observations.

23. A fit-for-work policy shall be in place, incorporating defined action levels for drugs (including prescribed medication) and alcohol.

24. A system shall be in place to manage driver fatigue.

DEFINITIONS

i. Light vehicle - A ”light vehicle” is a vehicle which:

• can be registered for use on a public road

• has four or more wheels

• seats a maximum of 12 adults (including the driver)

• that where registered, could be legally driven on a public roadway by a driver issued with a standard basic level – public road driver’s licence

• does not exceed 4.5 tonnes gross vehicle mass (GVM), which is the maximum loaded mass of the motor vehicle as specified by:

- the vehicle’s manufacturer; or

- an approved and accredited automotive engineer, if the vehicle has been modified to the extent that the manufacturers specification is no longer appropriate.

• Light vehicles may include the following categories of vehicles being used for work related activity:

owned or leased vehicles

- hire vehicles (for example Budget or Hertz rental vehicles)

- contractor or supplier vehicles operating on company property

- private vehicles used for work related activity.

SURFACE MOBILE EQUIPMENT

INTENT

To eliminate or minimise the risk of fatalities, injuries and incidents arising from the use of surface mobile equipment.

APPLICATION

This Protocol applies to surface mobile equipment such as rear dump, belly dump and water trucks, graders, dozers, and loaders. Where surface mobile equipment falls outside these groups, (e.g. draglines, shovels, excavators, forklifts, mobile cranes, buses, backhoes, bobcats, and other trucks larger than light vehicles), some requirements of this protocol may not be practicable, in these cases a risk-based approach shall be used to determine the level of compliance required with each of the specific requirements.

This Protocol applies to all controlled sites and controlled activities, and to all employees, contractors and visitors when involved in controlled activities.

REASON FOR INCLUSION

Surface mobile equipment has been involved in a significant proportion of fatal and high potential incidents. The causes and contributing factors to these incidents have been:

- overtaking

- ineffective communications

- loss of traction

- poor visibility

- overturning

- dropped loads

- reversing

- structural failure

- unplanned movements on slopes and inclines

- operator error due to fatigue and substance abuse

- parking protocols

- non-adherence to operating procedures.

REQUIREMENTS

The mandatory requirements of these Protocols are signified by the use of the word “shall”.

The word “should” indicates that the primary intent is to comply with the full requirements as if they were mandatory.

The risk management approach adopted must be consistent with the HSEC Risk Management Guideline and follow the Hierarchy of Controls.

The requirements of this Protocol are as follows:

A PLANT AND EQUIPMENT REQUIREMENTS

1. Surface mobile equipment shall have the following minimum safety specifications:

- seat belts for all occupants

- adequate lighting (e.g. headlights, tail, turn, brake, strobe, flashing light)

- identified isolation/lockout point in accordance with the Isolation Protocol

- adequate walkways, railing, steps/grab handle combinations and boarding facilities including an alternative path of disembarking in case of emergency

- extended front bumpers on mine haul trucks or adequate collision avoidance technology and/or procedures

- collision avoidance technology and/or procedures

- reversing alarms

- chock blocks for rubber tyred surface mobile equipment

- horn

- effective windscreen wipers

- effective guarding on accessible moving parts (consistent with the Equipment Safeguarding Protocol)

- signage on the equipment that allows clear and easy identification from a distance.

2. Surface mobile equipment should have the following minimum safety specifications, unless exempted by risk assessment:

- approved or certified roll-over protection

- a fire suppression system capable of being activated from both ground and cabin levels

- two-way radio or other forms of communication

- fall on protection

- enclosed and tightly sealed air-conditioned cabins, with consideration of requirements for noise and dust suppression systems and suitable protective glass (e.g. toughened, laminated, shatterproof)

- a method for transporting supplies and personal items to and from the operator cabin to enable drivers to continuously maintain three points of contact whilst mounting and disembarking equipment (e.g. a back pack or shoulder strap bag).

3. Advances in technology for collision avoidance, safety management systems, fleet management and visibility improvement, shall be monitored, and appropriate engineering reviews should be conducted to determine whether new technology should be implemented or used.

4. Design, inspection and maintenance requirements should be in place for all roadways including collision protection of hazardous and critical plant and equipment. Risk assessments should be carried out prior to any changes to traffic movements.

5. Safety berms shall be in place along roadways, excavations and dump areas as determined by risk assessment.

6. Layout of cabins should take into consideration the ergonomics of seating, operator controls, and retrofitted devices.

7. Fleet and control consistency should be considered where possible to minimise operator error when changing machines.

B. PROCEDURAL REQUIREMENTS

8. Seat belts shall be used in all cases for all occupants.

9. A formal risk-based selection and acceptance process shall be in place for all new (to site) and modified surface mobile equipment prior to commencement of work on site.

10. Selection of equipment, and any modification, shall be subject to a rigorous change management process.

11. A procedure and checklist system shall be in place for pre-operation inspection by the operator, including a brake functionality test. Log books shall be maintained and audited, and shall be located on the machine.

12. Procedures shall be in place to ensure surface mobile equipment only operates on sufficiently stable surfaces and on gradients that are within the limits of safe operation.

13. A post-maintenance machine test (scheduled or break down) shall be conducted.

14. On the job risk assessments shall be conducted as part of the planning process for surface mobile equipment operations, including maintenance and other activities.

15. A dust control and water management plan for roads, mining and haulage operations shall be in place. Consideration shall be given to extreme wet weather and the issue of over-watering roads.

16. Parking standards shall include requirements for the immobilisation of surface mobile equipment (e.g. chocking or ditches/trenches) and consideration for breakdown maintenance activities.

17. A maintenance and inspection program shall be in place for surface mobile equipment, including critical equipment and components.

18. A site-based traffic management plan should be in place including, but not limited to, the following:

- segregation of pedestrians, light vehicles and heavy mobile equipment where possible

- setting of appropriate speed limits, and installation and maintenance of road signage

- right-of-way rules (including overtaking restrictions)

- access planning in areas identified as hazardous and having significant associated risk

- systems to control movement of mobile equipment in areas accessible to pedestrians, into and out of workshops, and for controls on pedestrian and light vehicle movement around mobile equipment

- designated parking areas for heavy vehicles and light vehicles including around maintenance areas

- systems to control approaching, refuelling, parking, boarding, disembarking, and isolation by production and maintenance crews. Equipment operators or drivers shall be out of the cabin and dismounted onto ground level when their direct involvement with maintenance or servicing is not required

- guidelines for abnormal road conditions (e.g. rain, high winds) giving “go/no go” criteria and stating the responsible person for this decision

- clear communication procedures for interactions between all vehicles

- truck loading/unloading procedures - to avoid material or objects falling from the vehicle

- guidelines for wide or abnormal loads including offsite transport

- systems to control equipment use within the vicinity of overhead power lines.

19. Risk assessments shall be carried out prior to any changes to traffic movements or road systems.

20. Procedures should be in place which detail the maintenance which an operator is allowed to perform and that maintenance which personnel can carry out under testing conditions.

21. A tyre management system shall be in place to address issues including fire, heating, explosion, electrical contact, separations, maintenance, tyre changes, etc..

22. Mobile phones, whether hands free or not, shall only be used by the driver of surface mobile equipment whilst it is stationary and in a safe location.

C. PEOPLE REQUIREMENTS

23. Recruitment and induction processes for surface mobile equipment operators shall encompass past work history, site testing, and comprehensive medical examinations that confirm fitness for work.

24. Site and area induction of operators shall be performed prior to starting work in a new area.

25. A permit or certification system shall be in place to ensure drivers are competent to drive on site. In addition, a system shall be in place to verify that operators of vehicles have a valid drivers license prior to operating vehicles off-site.

26. A fit-for-work policy shall be in place, incorporating defined action levels for drugs and alcohol.

27. A system shall be in place to manage driver fatigue.

28. Behaviour based observations shall include the operation of surface mobile equipment. Any need for additional specific retraining shall incorporate the results of these observations.

UNDERGROUND MOBILE EQUIPMENT

INTENT

To eliminate or minimise the risk of fatalities, injuries and incidents arising from the use of mobile equipment underground.

APPLICATION

This Protocol applies to all underground mobile equipment, including rubber tyre mounted and rail mounted equipment designed specifically for underground use. Examples of underground mobile equipment covered by this Protocol include load haul dump machines, personnel transporters, multi-purpose vehicles, graders, and all mobile equipment with a machine mounted operator.

Where underground mobile equipment falls outside those mentioned above, a risk-based approach should be used to determine the level of compliance required with each of the specific requirements of this Protocol. Examples of underground mobile equipment excluded from this Protocol include crawler mounted equipment, shuttle-cars, continuous miners, and face production equipment without a machine mounted operator.

This Protocol applies to all controlled sites and controlled activities, and to all employees, contractors and visitors when involved in controlled activities.

REASON FOR INCLUSION

Underground mobile equipment is a core risk for underground operations. Several fatalities and high potential incidents have occurred involving underground mobile equipment. The causes and contributing factors to these incidents have been:

- interactions between vehicles/pedestrians e.g. passing or, working close by

- speeding

- non-adherence to operating procedures

- rolling and tipping over of vehicles

- unplanned inadvertent movements of vehicles down inclines and slopes

- operator error due to fatigue and substance abuse

- poor visibility.

REQUIREMENTS

The mandatory requirements of these Protocols are signified by the use of the word “shall”.

The word “should” indicates that the primary intent is to comply with the full requirements as if they were mandatory.

The risk management approach adopted must be consistent with the HSEC Risk Management Guideline and follow the Hierarchy of Controls.

The requirements of this Protocol are as follows:

A PLANT AND EQUIPMENT REQUIREMENTS

1. Underground mobile equipment shall have the following minimum safety specifications:

- roll-over protection for load haul dump machines

- operator overhead protection system (e.g. fall on protection system, canopy or cab structure)

- automatic reversing alarm (except for bi-directional machines, which shall be fitted with an automatic system to indicate direction of travel e.g. alternating light system)

- flashing light/s mounted on personnel transport vehicles, and underground light vehicles

- seat belts and/or passenger restraints

- fail to safe brakes, (excluding underground light vehicles)

- (with the exception of electrically operated equipment, for which a risk-based approach shall be used) an automatic or manual fire suppression system, in addition to a portable fire extinguisher

- restricted area and/or pinch point access controls or guarding where practicable (e.g. articulation locks for all articulated vehicles, with the locking mechanism able to be applied from a position of safety)

- a device to automatically immobilise a vehicle in the absence of an operator (the specific design requirements for this system should be determined using a risk assessment e.g. deadman type switch, automatic braking system, fail-safe door interlock smart card key system (excluding underground light vehicles)).

2. Design, selection, maintenance, and use criteria shall be in place for all remote controlled equipment.

3. Design and maintenance requirements shall be in place for all transport roadways. Roadway requirements may include, but not be limited to the following:

- safe operating width, height, inclination, gradient, surface

- demarcation of changed conditions

- traffic flow

- signage.

4. Risk assessments shall be undertaken as part of the design, selection, commissioning, operation, modification, and maintenance process for all underground mobile equipment.

B. PROCEDURAL REQUIREMENTS

5. A formal selection and acceptance process (including the requirements of the Fatal Risk Control Protocols) shall be in place for all new (to site) and modified underground mobile equipment prior to commencement of work on site.

6. A procedure shall be in place to ensure that mobile equipment stops to allow pedestrians to pass in underground roadways.

7. All people underground shall wear reflective clothing to a recognised standard (e.g. Australian Standard for High Visibility Safety Garments).

8. Parking rules shall be in place including, but not limited to, the following:

- engine should be shut down before the operator leaves the machine, except where safe operating procedures are authorised by the most Senior Manager of the operation, supported by documented risk assessment

- parking brakes shall be applied

- wheels should be turned into the rib/wall or chocked, and positioned as close to the rib/wall as possible

- all lifting and elevating attachments should be lowered or secured in the parked position when not in use.

9. A system shall be in place that identifies the maintenance and inspection requirements for underground mobile equipment (including locations where the mobile equipment should be located during the work).

10. A process shall be in place for pre-use and operational checks that clearly defines if mobile equipment is safe to operate.

11. Controls shall be in place to ensure the safety of people working in roadways, including work in and around unexpected breakdowns. The risk to any attendant employees or contractors shall be specifically addressed.

C. PEOPLE REQUIREMENTS

12. A competency based training system shall be in place for operation and maintenance of underground mobile equipment.

13. Key behaviours necessary to carry out activities associated with mobile equipment safely shall be identified.

14. A fit-for-work policy shall be in place, incorporating defined action levels for drugs and alcohol.

15. A system shall be in place to manage driver fatigue.

16. Behaviour based observations shall include the operation and maintenance of underground mobile equipment. Any need for additional specific retraining shall incorporate the results of these observations.

UNDERGROUND GROUND CONTROL

INTENT

To eliminate or minimise the risk of fatalities, injuries and incidents resulting from falls of ground and collapse in underground operations.

APPLICATION

This Protocol applies to all underground ground control planning and activities.

This Protocol applies to all controlled sites and controlled activities, and to all employees, contractors and visitors when involved in controlled activities.

REASON FOR INCLUSION

A significant proportion of fatalities and potentially fatal events in underground mines are connected with falls of ground and rock falls. The causes and contributing factors to these incidents have been:

- inadequate knowledge of ground stability characteristics at site

- lack of monitoring of effectiveness of ground supports

- working under unsupported ground

- at-risk barring and scaling down practices

- at-risk installation of support practices

- carrying out remedial support activities

- failure of ground support systems.

REQUIREMENTS

The mandatory requirements of these Protocols are signified by the use of the word “shall”.

The word “should” indicates that the primary intent is to comply with the full requirements as if they were mandatory.

The risk management approach adopted must be consistent with the HSEC Risk Management Guideline and follow the Hierarchy of Controls.

The requirements of this Protocol are as follows:

A PLANT AND EQUIPMENT REQUIREMENTS

1. The equipment design shall incorporate removal or separation of the operator from unsecured ground, or the equipment shall provide a physical barrier to protect the operator in the event of an uncontrolled ground movement from roof or walls.

2. Materials used in the ground support system shall be selected and routinely tested to ensure they meet the required specifications of the ground control plan.

3. Equipment used in the ground control system shall be maintained and tested on a regular basis to ensure that it meets the ground control plan requirements and specifications (e.g. long wall system health, torque settings for bolt installation, etc.).

4. Advances in ground control technology shall be monitored, and appropriate engineering reviews should be conducted to determine whether new technology should be implemented or used.

B. PROCEDURAL REQUIREMENTS

5. Design and selection of equipment used in ground control applications shall meet the requirements specified in the ground control plan.

6. Initial and ongoing geotechnical analysis and assessment shall be an integral part of the mine design process and carried out by a qualified and competent person/s.

7. As part of the change management process, geotechnical assessment shall be undertaken during modification to the mine operation or design.

8. In developing, implementing or altering any ground control system a geotechnical risk assessment process shall be undertaken.

9. Adequate contingency in ground control systems shall be provided by a multi-tiered ground support response plan.

10. A process shall be in place for assessing that ground is secure.

11. No person shall go beyond the area of secure ground.

12. Systematic collection and analysis of data shall be in place for management of prevailing and predicted conditions and to assist with pre-empting changes to the physical conditions.

13. Systematic and ongoing monitoring shall be in place that assesses the implementation and effectiveness of the ground control system.

14. Documented procedures shall be in place to ensure the safe and effective installation and removal of ground support.

15. A documented risk assessment shall be conducted before any remedial work is carried out to improve or regain stability, and appropriate risk reduction measures adopted.

C. PEOPLE REQUIREMENTS

16. The most Senior Manager of the operation shall authorise the ground control plan and is accountable for its implementation and ongoing effectiveness.

17. Roles and responsibilities shall be assigned to ensure implementation and management of the ground control plan.

18. A competency based training program shall be in place including, but not be limited to the following criteria:

- support design principles

- the ground control plan

- placement and removal of supports

- recognition of indicators of change that may affect ground stability

- on-the-job training and assessment

- requirements for reporting changes.

19. Suitably qualified, competent and experienced person/s shall be involved in the design, planning and implementation of the ground control plan.

20. A process shall be developed and maintained for the ongoing communication between the geotechnical team, operations management and operators.

21. Shift change procedures shall include the requirement to notify and document elevant personnel of changes to ground conditions and control.

22. Behaviour based observations shall include work and tasks associated with ground control systems. Any need for additional specific retraining shall incorporate the results of these observations.

DEFINITIONS

i. Secure ground is ground that is supported in accordance with the ground control plan, or unsupported ground, which has been assessed as not requiring support in accordance with the ground control plan.

ii. A multi-tiered ground support response plan is a plan in which additional levels of support may be added according to triggers defined under that plan.

HAZARDOUS MATERIALS MANAGEMENT

INTENT

To eliminate or minimise the risk of fatalities, illnesses, injuries and incidents arising from the storage, handling, production, transport, recycling and disposal of hazardous materials.

APPLICATION

This Protocol applies to hazardous materials that, in one or more of their forms (solid, liquid or gas), have the potential to lead to harm to people, the environment, or community (all stakeholders), either in an incident involving loss of control, or in normal, controlled activities (e.g. storage, handling, production, transport, recycling and disposal). This Protocol does not cover handling of explosives or radioactive materials.

This Protocol applies to all controlled sites and controlled activities, and to all employees, contractors and visitors when involved in controlled activities.

REASON FOR INCLUSION

Hazardous materials have caused several fatalities, continue to contribute to the number of significant incidents in, and are generally associated with all areas of the business. They are generally associated with uncontrolled releases and have the potential to affect a wide area around the incident (e.g. gases can travel significant distances). It is therefore necessary to ensure that equipment, processes, and behaviours are developed and adopted that will manage the risk associated with these materials. The causes and contributing factors to these incidents have been:

- at-risk maintenance activities

- lack of understanding of chemical properties and reactions

- at-risk manual handling activities

- insufficient management of risk

- equipment failure.

REQUIREMENTS

The mandatory requirements of these Protocols are signified by the use of the word “shall”.

The word “should” indicates that the primary intent is to comply with the full requirements as if they were mandatory.

The risk management approach adopted must be consistent with the HSEC Risk Management Guideline and follow the Hierarchy of Controls.

The requirements of this Protocol are as follows:

A PLANT AND EQUIPMENT REQUIREMENTS

1. The basis of design of a facility or process, permanent or temporary, which transports, produces, stores, uses or disposes of hazardous materials shall be reviewed, amended as necessary and documented utilising a process risk assessment tool such as HAZOP, HAZID, etc.. As-built design drawings (e.g. process and instrumentation diagrams, process flow diagrams, layout drawings, isometrics, etc.) shall be updated as a result of these reviews.

2. All specifications for the design and/or modification of hazardous materials facilities shall be subject to risk assessment that includes hazardous materials selection, transport, production, storage, handling, use and disposal. Previous incidents should be reviewed to ensure risk is as low as reasonably practicable (ALARP).

3. All facilities which have a significant risk from hazardous substances shall provide an emergency response plan which includes:

- means of escape in an emergency situation

- emergency response teams appropriate to the risk

- appropriate of safe refuge and assembly areas for people

- emergency response equipment for spillage containment, fires, explosions, burns, etc.

- appropriate response arrangements with external medical providers e.g. ambulance, hospitals, fire brigade etc.

- emergency response procedures appropirate to the hazadous materials and the risk

- recovery procedure and disposal of the hazardous material.

4. Provisions shall be made for safe venting, drainage and containment, where required by normal operation, emergency situations, based on a process risk assessment tool such as HAZOP and HAZID.

5. Labelling shall be in place on all storage vessels, containers and tanks, as per appropriate national or international standards. This labelling shall clearly identify the carried or stored material. Supporting information (e.g. material safety data sheets [MSDS]) shall also be readily available at the point of use and storage to identify appropriate first aid procedures.

6. Piping containing hazardous substances shall be marked such that the contents and direction of flow of the piping can be identified.

7. Security and access control systems and hardware shall be in place, appropriate to the risk, to manage access to areas where hazardous materials are stored and used.

8. Process control systems shall ensure that the potential for personnel to be exposed to hazardous materials is eliminated wherever possible or reduced to ALARP.

9. Automatic plant control systems should be in place in hazardous material facilities to eliminate the need for operator intervention and maintain operation within the required parameters. Such systems shall incorporate fail to safe systems in the event of emergencies. Where automatic control is not practicable, risk assessment shall be used to identify and implement operational options that reduce HSEC risk to ALARP.

10. Fixed and personal detection devices shall be considered as options in the selection of potential risk reduction measures.

These are the redesign and separation controls, and personal protective equipment as described in the Hierarchy of Controls (refer to requirement 11 of this Protocol).

B. PROCEDURAL REQUIREMENTS

11 Management of risk associated with hazardous materials shall be supported by a documented process that incorporates risk reduction using the Hierarchy of Controls, applied in the following order (a number of these options may be considered and applied individually, or in combination):

- Eliminate - the complete elimination of the hazard

- Substitute - replacing the material or process with a less hazardous one

- Redesign - redesign the equipment or work processes

- Separate - isolating the hazard by guarding or enclosing it

- Administrate - providing controls such as training, procedures, etc.

- Personal Protective Equipment – use appropriate and properly fitted PPE where other controls are not practical; impact minimisation equipment such as spill clean up or dust suppression measures.

12. A risk assessment process shall be in place for all hazardous materials to identify:

- the selection criteria and life cycle analysis for all hazardous materials

- the level of risk associated with the hazardous materials

- controls required to manage the risk to levels that are ALARP

- the performance requirements (reliabilities and capacities) of specific equipment and systems included in these controls.

13. A system shall be in place to identify and document maintenance, inspection, testing schedules and procedures for critical equipment associated with hazardous materials.

14. A system shall be in place whereby the introduction and disposal of hazardous materials, including containers, shall be approved by the site Hazardous Materials Co-ordinator (refer 28 below) prior to introduction or disposal.

15. A system shall be in place for the management of change of equipment and/or processes for transportation, storage handling, use and disposal shall include specific steps to assess the impact of changes on the risk associated with hazardous materials.

16. A site register shall be in place for all hazardous materials, and include the following:

- name

- HAZCHEM / Unites Nations code

- MSDS

- summary of maximum inventory

- storage requirements and precautions

- location, physical properties of the materials where they are used

- approved disposal methods.

17. A system shall be in place to ensure that MSDS are available to all personnel (including first aiders and medical personnel) involved in the transportation, storage, handling, use and disposal of hazardous materials on site.

18. A system shall be in place to ensure that all relevant design documents and drawings associated with this Protocol, are up to date, controlled and available.

19. Critical activities involving hazardous material, which have the potential for immediate or long-term harm, shall be identified and safe operating procedures documented, including transportation, storage handling, use and disposal of incompatible hazardous substances.

20. Safe operating limits for plant and equipment handling hazardous materials, which have the potential for immediate or long-term harm, shall be clearly defined, documented and available to operations and maintenance personnel.

21. Monitoring systems for hazardous materials shall be in place to ensure that the status of operation is understood and shown clearly at all times. These systems shall include the procedure for a documented hand-over between shifts that records any relevant information/changes in operating status.

22. A permit to work system shall be in place to ensure proper decontamination of plant and equipment, isolation, use of the correct personal protective equipment, and any special requirements or precautions (e.g. requirements for venting, clearing of piping or when using naked flames) where the occupational exposure limit of a hazardous substance could be exceeded.

23. A system shall be in place to control simultaneous operations involving hazardous materials to avoid mixing of incompatible materials.

24. Emergency response plans for hazardous materials incidents shall be in place and reviewed, tested and documented annually. This shall include external support services such as local ambulance and hospitals as appropriate to the risk

25. A system shall be in place to control and monitor access to areas where hazardous materials are stored and handled. This shall also identify process areas where hazardous materials may be released under certain operational circumstances (e.g. vent opening during process upset, infrequent discharge points) and what restrictions are placed on access to those areas.

26. A system shall be in place to authorise and control the training of appropriate personnel in normal transportation, storage handling, use and disposal of, and emergency response procedures for hazardous materials.

27. A system shall be in place to monitor short and long-term exposure of personnel to hazardous materials, which have the potential for immediate or long-term harm. This system shall ensure that fatality potential is also addressed.

28. Procedures shall be in place for transporting hazardous materials. Where required a hazardous material manifest and supporting documentation shall be completed and shipped with the hazardous material. This documentation shall comply with local legislation.

C. PEOPLE REQUIREMENTS

29. A site Hazardous Materials Coordinator shall be appointed at sites where hazardous materials are processed stored and handled. This person shall have training and be competent to understand and evaluate the risks associated with a wide variety of substances, and be able to identify where additional expert advice can be sourced. The individual shall be responsible for assessing the hazardous properties and disposal requirements of materials used, monitoring the consumption and management of inventory, and also provide an “as needed” service to supply, warehousing, operational and HSEC personnel.

30. The risk assessment process shall include people with relevant subject knowledge expertise. Consideration should be given regarding the use of external people (e.g. supplier technical officers).

31. A competency based training system shall be in place for operations, maintenance and emergency response roles involving hazardous materials. Use should be made of supplier expertise to supply this training with annual refresher courses if required.

32. Behaviour based observations shall include the operation of equipment and systems handling hazardous materials. Any need for additional specific retraining shall incorporate the results of these observations.

DEFINITIONS

i. HAZOP means hazard and operability study.

ii. HAZID means hazard identification.

iii. MSDS means material safety data sheet.

iv. HAZCHEM means hazardous chemical.

v. ALARP means as low as reasonably practicable.

MOLTEN MATERIALS MANAGEMENT

INTENT

To eliminate or minimise the risk of fatalities, injuries and incidents arising from the handling and processing of molten materials.

APPLICATION

This Protocol applies to operational activities in and around furnaces and smelters, and includes hazards associated with the processes of tapping, handling and transport of molten materials, and the operation of the smelting process. The additional requirements of the Hazardous Materials Management Protocol also apply to materials covered by the Molten Materials Management Protocol.

This Protocol applies to all controlled sites and controlled activities, and to all employees, contractors and visitors when involved in controlled activities.

REASON FOR INCLUSION

Molten materials have been involved in a number of fatalities in, and require specialist management equipment, processes, and competencies over and above those applied to handling of other hazardous materials. The causes and contributing factors to these incidents have been:

- inappropriate moisture levels

- loss of control during ladle movement

- water/metal contact

- personnel access control

- equipment failure due to heat

REQUIREMENTS

The mandatory requirements of these Protocols are signified by the use of the word “shall”.

The word “should” indicates that the primary intent is to comply with the full requirements as if they were mandatory.

The risk management approach adopted must be consistent with the HSEC Risk Management Guideline and follow the Hierarchy of Controls.

The requirements of this Protocol are as follows:

A PLANT AND EQUIPMENT REQUIREMENTS

1. The basis of design of molten material facilities shall be reviewed, amended as necessary and documented utilising the HAZOP and hazard analysis processes. As-built design drawings (e.g. process and Instrumentation diagrams, process flow diagrams, layout drawings, isometrics) shall be updated as a result of these reviews.

2. Design specifications for all new or modified facilities shall be subject to risk assessment and shall detail hazardous materials selection, storage, loading and unloading facilities, leading industry practices, applicable regulations and learnings from previous incidents.

3. All molten materials facilities shall provide for response to credible emergencies involving molten materials, including the provision for safe refuge and emergency response equipment for spillage containment, fires, explosions, burns, etc. and recovery and disposal of the molten material.

4. Alterations to the layout, risk control and mitigation equipment and systems shall be covered by the change management procedures.

5. Equipment associated with the handling and processing of molten materials will be designed to fail safe in the event of power failures, power dips and surges.

6. Automatic plant shutdown systems (local and remote to the hazard) shall be in place to eliminate the need for operator intervention to maintain operation within the design envelope.

7. Transport roads and rail systems for molten material carriers should, wherever possible, be dedicated for this purpose and clearly demarcated. Where this is not possible, risk analysis shall be undertaken to identify the additional controls required to manage the activities and potential conditions in the event of a molten material spillage, or loss of vehicle control and other hazards associated with transport over non-dedicated routes.

8. Molten materials processing and handling areas shall have sufficient emergency exits to provide at least two means of egress from any point.

9. Water supplies to molten material areas shall be limited to dedicated systems (e.g. jacket cooling) and free access to water tapping points eliminated, as far as practicable.

10. The tapping and casting processes should, wherever possible, be mechanised, automated and controlled from a remote location. Where this is not possible, risk analysis shall be undertaken to identify the additional controls required.

11. Restricted areas for handling and processing of molten materials shall be defined and demarcated, and compliance managed using a system of access controls. Where this is not possible, risk analysis shall be undertaken to identify the additional controls required.

12. Restricted areas and areas directly exposed to molten materials processing and handling risk shall be safeguarded to prevent personnel coming into contact with molten material, or hot surfaces. Risk analysis shall be undertaken to identify any additional controls required.

13. All surfaces in contact with molten materials shall be coated, prepared or of such a nature or grade that no exothermic reaction will occur when in contact with the molten material.

14. Molten materials processing and handling areas shall be designed to contain any spillage that may occur, and provide for safe clean up and disposal.

15. Molten materials processing and handling areas shall have general ventilation services, fume extraction facilities and emergency venting systems to minimise the exposure of people to dust, fume and gases.

B. PROCEDURAL REQUIREMENTS

16. All molten materials processing and handling shall be subject to risk assessment.

17. Procedures shall be in place for all molten materials processing, handling and safe disposal activities.

18. A system shall be in place to ensure that all process drawings are current, and are easily accessible to operations personnel.

19. Monitoring systems shall be in place to ensure that the status of operation is shown clearly at all times. These systems shall include the procedure for a documented hand-over between shifts that records any relevant information/changes in operating status.

20. The safe operating envelope for molten materials will be defined and understood by all process personnel. This shall include the indicators (physical, systems or observation based) that demonstrate that the limits of safe operation are being approached or have been breached (e.g. indicators of moisture present in systems containing molten metal).

21. Critical equipment shall be defined, and maintenance plans for that equipment shall be documented.

22. Emergency response plans shall be in place, and an annual simulation exercise shall be conducted as a minimum. Specialist first aid and pre-hospitalisation trauma care for injuries shall be a component of the emergency response services and shall be tested during simulation exercises.

23. A procedure shall be in place to provide a quarantined store for alloys and other material to be recycled into systems containing molten materials so as to prevent explosions, contamination or other uncontrolled reactions.

24. A procedure that has the approval of the local traffic authorities shall be in place for the vehicle transportation (other than rail) of any molten materials along, or crossing public roads, over railway level crossings and past, or through, residential areas.

25. The management of change process for any operation shall include specific steps to assess the impact of changes on the risk associated with molten materials.

C. PEOPLE REQUIREMENTS

26. The roles and responsibilities for molten materials processing and handling shall be defined and assigned.

27. A competency based training system shall be implemented for operation and maintenance roles involving molten materials processing and handling.

28. All personnel shall be trained in their duties and responsibilities under emergency conditions.

29. All personnel shall be trained on the potential acute health effects of their working conditions and the materials handled.

30. The use of effective personal protective equipment shall be monitored and enforced in all areas where this type of control is required.

31. A fit-for-work policy shall be in place, incorporating defined action levels for drug and alcohol and fatigue management plan.

32. Behaviour based observations shall include the operation of equipment and systems handling molten materials. Any need for additional specific retraining shall incorporate the results of these observations.

EQUIPMENT SAFEGUARDING

INTENT

To eliminate the risk of fatalities, and injuries where and when there is the potential for human interaction with moving parts or potential moving parts of plant and equipment.

APPLICATION

This Protocol applies to safeguarding of people from moving parts of plant, mobile machines, equipment and power tools, including moving equipment, high pressure equipment and applications, electrical, and other energy sources with the potential to move, and objects falling or projected from moving parts.

This Protocol applies to all controlled sites and controlled activities, and to all employees, contractors and visitors when involved in controlled activities.

REASON FOR INCLUSION

A number of high potential and fatal incidents have been associated with the inadequate and inappropriate safeguarding. The causes and contributing factors to these incidents have been:

- absent or inadequate guarding in place

- working alongside unguarded moving parts

- no process to identify guarding needs

- struck by objects falling or projected from moving parts

- ineffective guarding standards in place

- struck by equipment mobilized by high pressure equipment

- working on moving parts with guarding removed

- lack of guarding interlocks on potential high risk plant and equipment.

REQUIREMENTS

The mandatory requirements of these Protocols are signified by the use of the word “shall”.

The word “should” indicates that the primary intent is to comply with the full requirements as if they were mandatory.

The risk management approach adopted must be consistent with the Risk Management Guideline and follow the Hierarchy of Controls.

The requirements of this Protocol are as follows:

A PLANT AND EQUIPMENT REQUIREMENTS

1. New plant and equipment shall consider all energy sources and be designed to eliminate the need for guarding where practicable. Safeguarding shall be selected where other potential mitigation measures do not adequately protect personnel as identified in the risk assessment in line with requirement 7 of this protocol.

2. Plant and equipment safeguards shall be designed and constructed to comply with relevant legislation, standards, codes of practice and relevant recognised leading industry practices and considering maintainability and operability.

3. A formal system shall be in place to ensure the integrity of plant and equipment safeguarding.

4. Where safeguarding and interlock systems are insufficient to protect people, access to plant and equipment shall be controlled and monitored.

5. Fail-to-safe switches or devices shall be installed on all manually operated rotating plant and equipment and power hand tools (e.g. saws, lathes, drill presses, etc.).

6. Guards shall only be removed for maintenance and repair after plant and equipment has been isolated, locked out and tested in line with the Isolation Protocol. Where the temporary removal of safeguards is necessary on operating plant and equipment, for the purposes of fault finding, testing and commissioning, a risk-based procedure shall be in place. Guards shall be replaced prior to plant and equipment being put back into operation.

B. PROCEDURAL REQUIREMENTS

7. A risk based process shall be used to identify where safeguarding and interlocks are required on plant and equipment.

8. A risk-based process shall be used to identify safeguarding hazards that require interlock systems as an additional control.

9. All documentation related to the risk based process for the selection and modification of safeguarding requirements shall be retained and controlled.

10. A change management system shall be used to ensure the integrity of safeguarding is optimal when change occurs.

11. No guarding shall be modified or altered except through the application of a risk-based change management process.

C. PEOPLE REQUIREMENTS

12. A competency based training system that includes the requirements of this Protocol shall be in place for relevant personnel involved in the design, purchase, construction, operation and maintenance of plant and equipment.

13. Behaviour based observations shall include work activities associated with plant and equipment safeguarding. Any need for additional specific retraining shall incorporate the results of these observations.

ISOLATION

INTENT

To eliminate or minimise the risk of fatalities, injuries and incidents arising from the uncontrolled release of energy or hazardous materials.

APPLICATION

This Protocol applies to the isolation of all sources of energy (electrical, mechanical, hydraulic, chemical, gravitational, pneumatic, kinetic, stored energy etc.).

This Protocol applies to all controlled sites and controlled activities, and to all employees, contractors and visitors when involved in controlled activities.

REASON FOR INCLUSION

A significant proportion of our potential fatalities have included steps where sources of energy were not isolated adequately.

The causes and contributing factors to these incidents have been:

- failure to identify or recognise a source of potential or stored energy

- inadequate training or competence

- inadequate lockout/tag out systems

- complacency

- working on, or isolation of, the wrong equipment

- inadequate design/maintenance of isolators.

REQUIREMENTS

The mandatory requirements of these Protocols are signified by the use of the word “shall”.

The word “should” indicates that the primary intent is to comply with the full requirements as if they were mandatory.

The risk management approach adopted must be consistent with the Risk Management Guideline and follow the Hierarchy of Controls.

The requirements of this Protocol are as follows:

A PLANT AND EQUIPMENT REQUIREMENTS

1. Purchase and design of equipment (including hired and contracted equipment) shall give due consideration to meeting the requirements of this Protocol.

2. Isolation shall provide positive protection and be achieved by the use of locking devices or the establishment of a physical barrier or separation. All separations or physical barriers shall be provided with either a permanent or temporarily fitted locking device.

3. Personal locking devices shall:

- be uniquely keyed

- not be combination locks

- not have an unauthorised second-party master override key

- be kept under the exclusive control of the owning individual, and key(s) shall not be transferred to another person for lock removal.

4. Designated isolation points shall be clearly labelled at all times to identify the circuit or system over which they have direct control. These labels shall be applied following a process of pre-isolation identification using isolation lists, marked drawings etc. (where permanently applied, these labels shall be physically verified prior to the isolation).

5. Lockout boxes, stations or equivalent shall be provided where required.

6. All designated isolation points fitted with personal locking devices shall be tagged. The isolation tagging system shall ensure that:

- isolation points are positively identified, including the name of the person locking out

- the reason for the isolation is clearly identified

- isolation tags are highly visible to prevent inadvertent operation.

B. PROCEDURAL REQUIREMENTS

7. All sites shall have a documented isolation lockout and tag out system. An additional overall isolation and lockout guideline shall be in place, and include definitions of appropriate treatment for routine isolations, non-routine isolations, group, master and/or multiple isolations, short-term isolations and long-term isolations (“mothballing” procedures are only required prior to such activity).

8. The isolation system shall be applied to all activities on site, including contractor activities (e.g. construction, commissioning, operation, maintenance, return to service, emergency, modification or demolition of equipment).

9. The isolation guideline should use a risk-based process to determine the appropriate isolation method for any activity (either by way of a full description for specific cases, or by demonstrating the process that shall be followed to achieve the appropriate level of isolation in new activities). This shall include, but not be limited to:

- the role of work instructions, checklists, tagging requirements and the permit to work system

- a positive registration process for people working on isolated equipment (personal tag, log sheet etc.)

- changed requirements associated with the duration of the isolation and task/s, or when tasks take longer than planned to complete

- energy sources to be isolated (hazardous materials, mechanical, electrical etc.)

- the physical state of the energy sources such as their phase (liquid, solid, vapour etc.) and other characteristics (e.g. pressure, temperature, voltage etc.)

- controls required for the duration of the activity (temporary engineering and operating changes, emergency procedures, personal protective equipment, etc.)

- the requirements for formal contact with representatives in charge of each facility area affected, and the process for granting written authorisation to proceed

- special precautions when isolations cover one or more shift changeovers.

10. Documented system-specific isolation procedures shall be in place for critical equipment (such as critical alarms, emergency shutdown devices, relief and blow-down valves, fire and gas detection and protection devices, and other items as designated in the critical equipment register).

11. Documented test procedures shall be provided to verify isolation integrity including, but not limited to the following principles:

- identification of all energy sources or hazardous materials directly and indirectly associated with the work to be performed

- confirmation of those systems requiring isolation

- isolating the confirmed energy or hazardous material sources

- application of lock/tag

- application of isolation tag

- trying/testing of all systems and non-redundant isolations when reasonably or feasibly possible (to verify the integrity of the isolation and ensure a zero energy state exists).

12. A formal procedure shall be in place for controlling clearances to work for the:

- isolation and de-isolation of plant and equipment

- handover and hand back of plant and equipment between operation and maintenance

- transfer of isolations between shifts or different workgroups.

13. Specific procedures shall be developed to address software overrides.

14 A procedure shall be in place to mitigate hazards in special cases where any one of the following is not achievable:

- a zero energy state

- a test/try of isolation is not possible, or

- use of a locking device is not feasible.

15. Formal isolation procedures shall include requirements for investigation, reporting and removal of personal locks/tags by an authorised person other than the originator.

16. A system shall be in place for the management of change of equipment and/or processes for the isolation system, or installed isolations, and shall include specific steps to assess the impact of changes on the risk associated with these changes.

This system shall include, but not be limited to:

- changes to process conditions

- purchase/installation of new equipment

- modifications to existing equipment including software changes and overrides

- internal and external incident findings and learnings

- the need for revision of the system and/or guideline and/or additional training.

17. The isolation system shall be regularly reviewed and audited to capture any previously unidentified changes and revised when necessary.

C. PEOPLE REQUIREMENTS

18. Roles and responsibilities for electrical, mechanical, or process isolation management shall be defined.

19. A competency based training system and field assessment shall be in place to approve personnel before they conduct isolation processes.

20. Behaviour based observations shall include tasks and activities associated with isolation. Any need for additional specific retraining shall incorporate the results of these observations.

DEFINITIONS

i. A system or isolation tag is a tag applied to an isolation point by the person who is responsible that the isolation requirements for the task have been met and is a tag that when applied prohibits all use, operation or start-up of plant and/or equipment.

ii. Routine work is work that does not require a permit and is covered by a procedure, work instruction or checklist.

iii. Non-routine work is any activity that is outside the regular operation of the site. Non-routine work is not normally covered by a management system procedure, work instruction or checklist, and can involve an activity where more than one energy source has to be isolated.

iv. A group isolation is achieved when there is a single common isolation point that isolates more than one unit of equipment.

v. A multiple isolation is a single isolation point that is locked and/or tagged by more than one person.

vi. A short-term isolation is an isolation in place for one shift period or less.

vii. A long-term isolation is an isolation in place for more than one shift period.

viii. Software overrides are those that either electronically set and hold a device or electronically defeat an output action for emergency and safety shutdown systems. Their functions are electronically initiated and applied to control rather than power circuits.

ix. Personnel locking device is one that is provided to an individual for the purpose of their own protection. It is not to be used by others, and can only be removed by the owner. The only exception is the site master key that can be used by the the most Senior Manager at the operation.

x. Personal danger tag is a tag personally applied by the individual prior to commencing work on the isolated plant or equipment. The individual who placed the personal danger tag on the isolated piece of plant or equipment is the only person who can remove the tag. The only exception for removal of the tag by others is when the most Senior Manager at the operation, who must ensure the individual has left the site or operation, has given approval.

WORKING AT HEIGHTS

INTENT

To eliminate or minimise the risk of fatalities, injuries and incidents arising from working at heights.

APPLICATION

This Protocol applies wherever there is potential for any person to fall 2 metres or more, or to gain access to within 2 metres of an open edge from where there is the potential to fall 2 metres or more, including working from various forms of portable and moveable elevated work platforms, cages, ladders, scaffolding and where objects could fall and cause injuries. Risk assessment may identify high potential fall hazards when working at heights of less than 2 metres in which case this protocol shall be applied. (Note: if local legislation requires more stringent controls, then those controls shall be implemented.)

This Protocol does not apply to rope rescue situations and abseiling that are regarded as specialist functions. This Protocol applies to all controlled sites and controlled activities, and to all employees, contractors and visitors when involved in controlled activities.

REASON FOR INCLUSION

Falls from heights have contributed to a significant proportion of our fatal and high potential incidents. The causes and contributing factors to these incidents have been:

- failing to wear a harness

- lack of job planning and job assessment

- wearing the wrong sort of harness

- unstable set up of elevated work platforms

- wearing the harness incorrectly

- unguarded or unbarricaded hole, edges, voids, excavations or walkways.

REQUIREMENTS

The mandatory requirements of these Protocols are signified by the use of the word “shall”.

The word “should” indicates that the primary intent is to comply with the full requirements as if they were mandatory.

The risk management approach adopted must be consistent with the Risk Management Guideline and follow the Hierarchy of Controls.

The requirements of this Protocol are as follows:

A PLANT AND EQUIPMENT REQUIREMENTS

1. All working at heights equipment shall comply and be used in accordance with relevant approved design standards and manufacturers specifications.

2. Single person anchor points shall be capable of withstanding 15kN (approximately 3,372lbf). Where it is not practical to install dedicated anchor points (i.e. ad hoc work), anchor points capable of withstanding 15kN shall be identified through a risk assessment process and shall be approved by a competent person prior to commencement of work.

3. Where personnel are required to work within 2 metres of an opening where they could fall, they shall use personal fall restraint equipment, such as a fixed lanyard and harness as a minimum, which will prevent them from falling over the edge.

4. Where there is potential to fall more than 2 metres, personnel shall wear appropriate personal fall arrest equipment. In such circumstances a full body harnesses, including shock-absorbing lanyard or inertia reel, is mandatory. The use of body belts for fall arrest is prohibited, except for specialised tasks such as pole-climbing belts worn by specially trained linesmen.

5. All forms of portable and movable elevated work platforms and suspended work cages shall conform to relevant approved design standards. People in the work platform basket shall wear a correctly fitted harness attached by a lanyard to a suitable anchor point in the basket. This does not apply to people working from a properly constructed and certificated scaffold with the requisite handrails and toe boards.

6. Where there is potential to fall more than 2 metres in unprotected areas, access shall be restricted and controlled through risk assessment e.g. stockpile feeder chutes, highwalls, water hazards, wharves, etc..

7. Where operators need to gain access to places at height on large plant and mobile machinery regularly (e.g. to clean windscreens or filters), then access ways should be provided. Ideally these access ways should have handrails. Where handrails cannot be installed, then fall restraint or fall arrest equipment should be considered dependant on the outcome of a risk assessment of each situation.

B. PROCEDURAL REQUIREMENTS

8. The risk of fall shall be eliminated where reasonably practicable utilising the Hierarchy of Controls.

9. Standard work procedures shall be in place for the correct wearing and use of personal fall arrest and fall restraint equipment.

10. There shall be a work permit system in place to control all working at heights.

11. A documented risk assessment shall be conducted before the commencement of work and at any time the scope of work changes or the risk of a fall increases. The risk assessments shall include:

- consideration for the potential of objects, as well as personnel, to fall

- selection of appropriate control measures using the hierarchy of controls

- the possibility for weather and other environmental conditions to influence the working conditions (e.g. wind, rain, snow, dust, gases, poor lighting, temperature etc.)

- selection of appropriate equipment

- selection of anchor and tie off points

- condition of supporting structures such as roofs

- selection of appropriate barricading and/or demarcation

- fall clearances i.e. length of lanyard + tear-out distance + height of user + safety margin.

12. All equipment shall be fit-for-purpose and undergo pre-use checks and a minimum of six–monthly (bi-annual) documented inspections by a competent authorized person. An equipment register and tagging system shall be in place to indicate compliance with this inspection. Testing shall be done in accordance with recognised standards.

13. Where the work method requires persons to detach and re-attach at height, a dual lanyard system shall be utilised to ensure that at least one connection point is maintained at all times.

14. Where the use of personal fall arrest equipment is required, a person shall not work alone and there shall be other personnel in the vicinity that can raise the alarm immediately should a person fall.

15. Persons working at height shall ensure that their safety helmets are secured by using a helmet chinstrap to retain the helmet on the head.

16. A system should be in place to prevent tools, materials and other objects from falling from height.

17. Barricading and warning signage should be placed on all lower levels where personnel or objects may fall.

18 Personnel operating elevated work platforms and cages shall be trained and certified for the specific equipment they are using.

19. The site emergency response plan/s should include plans for the rapid retrieval of personnel in the event of a fall from height i.e. response time is critical if a person is to avoid suspension trauma.

C. PEOPLE REQUIREMENTS

20. Sites shall conduct a process to ensure selected personnel are fit to work from heights. Specific consideration shall be given to personnel who suffer medical conditions, such as vertigo and epilepsy, as well as considering the weight of the person using the harness. (Note: many harness systems have a maximum weight limit of 136kg/300lbs.)

21. A competency based training program for employees and supervisors shall be in place, which includes provisions for maintaining competence. All persons engaged in work covered by this Protocol shall be adequately trained and assessed for competency.

22. Behaviour based observations shall include activities and tasks associated with working from heights. Any need for additional specific retraining shall incorporate the results of these observations.

DEFINITIONS

i. Fall restraint means an approved device and any necessary components that function together to restrain a person in such a manner as to prevent that person from falling to a lower level.

iii. Fall arrest system means the use of multiple, approved safety equipment components such as body harnesses, lanyards, deceleration devices, droplines, horizontal and/or vertical lifelines and anchorages, interconnected and rigged as to arrest a free fall.

iii. Fall prevention means the design and use of a fall prevention system such that no exposure to an elevated fall hazard occurs. This may require more than one fall prevention system or a combination of prevention or protection measures.

iv. Suspension trauma is the effect that can occur when a person’s legs are immobile in an upright posture for a prolonged period, after an arrested fall with a fall-arrest system. The person is suspended and caught in an upright, vertical position and the harness straps cause pressure on the leg veins. The blood flow to the heart is reduced, resulting in fainting, restriction of movement or loss of consciousness. This may lead to renal failure and eventually death, depending on a person’s susceptibility. The condition may be worsened by heat and dehydration.

v. Fixed lanyard is a line used as part of a lanyard assembly to connect a harness to an anchorage point or a static line in situations where there is risk of a fall.

vi. Inertia reel (also known as a self-retracting lanyard or fall-arrest block) is a mechanical device that arrests a fall by locking onto a drop line and at the same time allows freedom of movement.

vii. Barricading is defined as a physical barrier that prevents inadvertent access to an area e.g. handrails, access doors and gates or similar installations, temporary or permanent. Barrier tape does not qualify as barricading.

viii. Demarcation is defined as any method that indicates that an area is used for a specific purpose, or that access is restricted. Examples are barrier tape, painted lines on floor surfaces, portable signs denoting drop zones or no access past a specific point.

LIFTING OPERATIONS

INTENT

To eliminate or minimise the risk of fatalities, injuries and incidents arising from the performance of lifting operations.

APPLICATION

This Protocol applies wherever lifting operations are undertaken. It includes lifts involving owned, hired or contracted cranes such as mobile, crawler, tower, derrick, portal and pedestal-type, vehicle loading cranes, electric overhead travelling cranes, and monorail cranes. The Protocol also applies to lifting equipment including slings, chains, wire ropes, shackles, pad-eyes, containers, baskets, tuggers, winches, man-riding winches, work-belts, harnesses, work and personnel transfer baskets.

In addition to the manufacturer’s standard safety features, local statutory requirements, or in the absence of these, ISO Standards, the following minimum safety features shall or should be included as indicated.

This Protocol applies to all controlled sites and controlled activities, and to all employees, contractors and visitors when involved in controlled activities.

REASON FOR INCLUSION

A significant proportion of our fatal and Significant Incidents have occurred in the course of lifting and crane operations.

Identified causes and contributing factors include:

- lack of job planning and hazard assessment

- incorrect selection of cranes and lifting equipment for the task

- inadequate knowledge of lifting operations by personnel involved

- inadequate inspection, maintenance, tagging and storage of lifting equipment

- lack of training in correct use of lifting equipment

- lack of competence in lifting operations

- incorrect use of cranes and lifting equipment including poor practices such as out-of-vertical loading and over loading

- poor recognition of unsafe conditions including environmental conditions

- operation of cranes and lifting equipment with safety and warning devices overridden, inoperable or illegible

- incorrect design of cranes and lifting equipment.

REQUIREMENTS

The mandatory requirements of these Protocols are signified by the use of the word “shall”.

The word “should” indicates that the primary intent is to comply with the full requirements as if they were mandatory.

However, there will be circumstances where local conditions may demonstrate that the requirement is either not applicable or an alternative approach is necessary. In cases where “should” has been used in a requirement, variation can only be considered as compliance if the most Senior Manager of the operation approves it based on an evaluation of the risk. The risk management approach adopted must be consistent with the Risk Management Guideline and follow the Hierarchy of Controls.

The requirements of this Protocol are as follows:

A PLANT AND EQUIPMENT REQUIREMENTS

1. All electrical cranes shall have power supply isolation points capable of being positively locked.

2. Cranes shall be ergonomically acceptable to the site and have fall protection systems provided for their operation, maintenance and inspection.

3. Cranes without a physical locking system that disables and isolates its free-fall capability, shall not be used.

4. Electric overhead travelling and portal cranes should have overload protection.

5. Crane cabins should be air-conditioned or heated in accordance with environmental conditions.

6. All crane cabins shall have signs to warn against interruption of the operator.

7. Vehicle loading cranes shall have sufficient engineering controls to prevent the operator from being crushed during lifting operations.

8. All crane hooks shall be fitted with a positive locking safety catch.

9. The safe working load (SWL) or working load limit (WLL) shall be clearly identified and marked on all cranes and relevant lifting equipment and shall not be exceeded.

10. Load cells, load moment indicators and external rated capacity lighting shall be available in accordance with the table below.

11. All cranes and lifting equipment shall comply with the requirements of the relevant approved design standard. The minimum acceptable design standard shall be the relevant ISO standard. In countries where the requirements of the relevant national standard exceed the requirements of the ISO standard, the national standard shall apply.

12. All cranes and lifting equipment shall be identifiable with a unique identity code or number.

13. A competent person shall determine the maximum environmental conditions under which cranes and lifting equipment can be safely used. Except in the event of an emergency, cranes and lifting equipment shall not be put into service if the maximum environmental conditions are exceeded. Risks shall be assessed in emergency situations.

14. Items of lifting equipment that are subject to wear and frequent replacement (e.g. slings, shackles, pad-eyes, shipping and handling baskets) or used to transport equipment to and from sites, shall be colour coded to confirm compliance with certification and inspection requirements.

B. PROCEDURAL REQUIREMENTS

15. A formal selection and acceptance process based on risk assessment shall be in place for all new (to site) and modified lifting equipment, taking into account the crane’s various safety features and cabin ergonomics, prior to commencement of work.

16. Manufacturer’s crane and lifting equipment operating manuals and load charts shall be available to the crane and lifting equipment operator. These should be in the language of the country in which the lifting equipment is being used.

17. Where the crane and lifting equipment operator is not conversant with the language of the country, provisions shall be made to ensure that the operators can understand the operating manuals and load charts.

18. A procedure shall be in place to address:

- lifting operations when the arcs of operation of two or more cranes can overlap*

- multiple crane lifting operations*

- the danger to lifting operations when adverse weather conditions are present or imminent e.g. electrical storm, high winds and sea state

- people safety when cranes and lifting equipment are operating in the proximity of live electrical conductors*

- lifting operations when lifting near or over unprotected plant, equipment or services, including live process or hydrocarbon processes*

- the effective hand-over from one operator to another for cranes with complex boom, jib or tower configurations

- availability and use of check-lists for pre and post-operational inspections.

Detailed lifting plans are required for points above marked “*” and shall be approved by a competent supervisor. Toolbox meetings shall be held prior to such lifts to ensure all personnel understand how it is to be executed.

19. Cranes shall not be used for lifting operations until crane operators have been given sufficient time to familiarise themselves with relevant aspects of the crane.

20. Risks associated with all lifting, crane maintenance, assembly activities and environmental conditions shall be assessed as part of the planning process. Barricading, warning signs or other means of ensuring personnel protection shall be in place during lifting operations and for those cranes left unattended in wind vane mode.

21. There shall be no side loading of crane booms.

22. With the exception of pick and carry operations, no lifting shall be carried out without outriggers being deployed and locked.

23. Controls shall be in place to prevent objects from lifting equipment and loads falling from above.

24. The lifting of personnel with cranes shall only be carried out using approved workbaskets or cages. Cranes used for this purpose shall be approved as suitable for man-riding operations. A recovery plan should be in place before personnel are lifted.

25. The elimination of the need to work under suspended loads shall be pursued. Where working under suspended loads is unavoidable, controls shall be in place to eliminate or minimise the risks to personnel.

26. Any modification to cranes and lifting equipment shall be subject to the original equipment manufacturer’s approval and to a rigorous change management process.

27. A preventative maintenance system should be in place to ensure that all cranes and lifting equipment is maintained and in a serviceable condition.

28. All cranes and lifting equipment shall be inspected and tested (including non-destructive testing as required by the relevant standard) prior to being operated or put into service. After any repair and/or modification, cranes and lifting equipment shall be inspected (and non-destructively tested as required by the relevant standard) prior to being returned to service.

29. A system of periodic inspection shall be in place for all cranes and lifting equipment. Lifting equipment shall be visually inspected and confirmed fit for purpose prior to being put into service. Visual inspection of lifting equipment by approved competent person should be performed on a regular basis (e.g. six monthly) unless regulations in the local area require examination more frequently.

30. A register of all lifting equipment should be maintained. This should include:

- equipments unique identifi cation number

- documentary evidence of all inspections

- certifi cations

- maintenance

- modifi cations and tests.

C. PEOPLE REQUIREMENTS

31. Suitably qualifi ed, certifi ed and competent person/s shall be involved in the planning, supervision and implementation of the lifting operations.

32. The roles and responsibilities for lifting operations shall be clearly defi ned.

33. A competency based training programme for contractors, employees and supervisors shall be in place. An approved examiner should assess the competency for trainers performing such training.

34. A competent inspector shall perform lifting equipment inspections. An approved examiner should assess the competency of the lifting and handling equipment inspector.

35. Crane operators and crew shall be able to communicate in a common language and to use the correct crane signals.

36. Sole crane operators shall also be trained in slinging practices.

37. A fi t-for-work policy shall be in place, incorporating defi ned action levels for drugs and alcohol and a fatigue management plan.

38. Behaviour based observations shall be performed and any need for additional specifi c training shall incorporate the results of these observations.

DEFINITIONS AND TERMINOLOGY

i. Lifting operations means any operation using a crane and lifting equipment that involves the raising and lowering of a load, including the suspension of a load.

ii. Lifting equipment refers to any device which is used or designed to be used directly or indirectly to connect a load to a crane and which does not form part of a load, eg. Wire rope slings, chain slings, man made fi bre slings, hooks and fittings, swivels, shackles, eye bolts, rigging screws, wedge sockets, plate clamps and lifting beams.

iii. External rated capacity lighting refers to clearly visible green, amber and red lights mounted externally to the Crane, green to indicate safe operating range, amber when approaching maximum rated capacity and red when maximum rated capacity has been exceeded.

iv. Workbasket refers to a personnel carrying device designed to be suspended from a Crane.

v. Lifting crew are persons working directly with a Crane operation.

vi. Banksman (also referred to as a rigger/dogman) is a person empowered to apply slinging techniques, including the selection and inspection of lifting accessories and directing the crane operator in the movement of the load, including when the load is out of view of the operator.

mining engineering

Friday, September 17, 2010

Fatal Risk Control Protocols

arsip mining engineering