General Site Safety Rules REVISION #21

Transcription

1 General Site Safety Rules REVISION #21 ALUMINIUM METAL PRIMARY PRODUCTION KURRI KURRI

2 Dear Inductee, Welcome to the Hydro Aluminium Kurri Kurri General Site Safety Induction. Please take a few minutes to read the information on this page - it just might help you! Q: How do I "pass" the induction? A: The simplest and easiest way to be successful on your first attempt at the induction is to READ THE HANDBOOK and complete the "Self Test" questions contained at the end of each section. Experience has shown that people who do not read the handbook do not pass the induction. If you want to avoid the hassle of sitting a retest, then READ THE HANDBOOK. Q: What do I need to bring with me to the induction? A: You will need to bring the following items to the induction: 1. Your copy of the "" Handbook 2. Photo identification (eg. drivers licence, passport) 3. Your WorkCover certificates (if applicable) If you do not bring all of these items with you, then you may be refused the right to undertake the induction and required to book in again to do the induction on another day. Q: What will happen if I do not "pass" the induction? A: If you do not pass the induction on your first attempt you will be required to book in at the Gatehouse to redo the assessment. Retests are generally held at 6.30 am, Monday to Friday. Q: What do I need to bring with me to the retest? A: You will need to bring your photo identification (eg. drivers licence, passport). If you do not have an acceptable form of identification with you, then you will not be permitted to do the retest. Q: What if I don't "pass" the retest? A: If you do not pass the induction on your second attempt you may be required to undergo the entire induction process again. So make sure you READ THE HANDBOOK to avoid this happening to you. Good Luck!

3 Hydro Aluminium Kurri Kurri Pty Ltd CONTRACTOR SITE INDUCTION DETAIL FORM ID NO: CARD NO: PASSPORT NO: GIVEN NAMES: SURNAME: SEX: DATE OF BIRTH: YOUR ADDRESS: POSTCODE HOME PHONE: MOBILE NO: CONTACT PERSON (FOR EMERGENCIES): EMERGENCY PHONE NUMBER (S): COMPANY NAME: COMPANY ADDRESS: POST CODE: COMPANY PHONE NUMBER: YOUR JOB CLASSIFICATION: HYDRO DEPARTMENT: HYDRO SUPERVISOR: WORKCOVER TICKETS HELD: WORKCOVER LICENCE NUMBERS: Statement of Agreement: I, the undersigned, have reviewed and understand the information contained in the Hydro Aluminium Kurri Kurri Pty Ltd General Site Safety Rules and agree to conform to the requirements outlined in the booklet. The information I have provided regarding my personal details is, to the best of my knowledge accurate. Signed: Date: Office Use Only Were ALL critical questions given a - Yes / No Applicant is: Competent Knowledge Not Yet Competent Comments/Feedback (Assessors to make any additional comments which clarify the assessment). Date of Assessment:

4 Hydro Aluminium Kurri Kurri Pty Ltd CONTRACTOR SITE INDUCTION DETAIL FORM ASSESSMENT NO: ANSWER SHEET ASSESSED BY: C.1. C.6. C.11. C.16. C.21. A. A. A. A. A. B. B. B. B. B. C. C. C. C. C. C.2. C.7. C A. A. A. A. A. B. B. B. B. B. C. C. C. C. C. C.3. C.8. C.13. C.18. C.23. A. A. A. A. A. B. B. B. B. B. C. C. C. C. C. 4. C.9. C.14. C.19. C.24. A. A. A. A. A. B. B. B. B. B. C. C. C. C. C. C C.15. C A. A. A. A. A. B. B. B. B. B. C. C. C. C. C. APPLICANT'S SIGNATURE: DATE: ASSESSOR'S SIGNATURE: DATE:

5 GENERAL INSTRUCTION 1. Review and understand the contents of this booklet before you undertake the site 'General Induction'. 2. If you are a contractor, complete the Contractor Site Induction detail form and sign the statement of Agreement. Employees will be provided with a separate form. 3. Bring this booklet (and completed form as per point 2) to the site 'General Induction' Remember all the requirements outlined in this booklet are designed to protect the health, safety and wellbeing of all persons on site. Our Goal is ZERO - ZERO Injuries - ZERO Defects

6 C O N T E N T S Introduction Safety at the Smelter 1 Section No 1 The Induction System The General Site Safety Induction 2 The Pass Book 3 Visitors 4 What the General Site Safety Induction Does Not Cover 5 What Work the General Site Safety Induction Will Not Let You Do 6 Revision 7 Section No 2 Prohibited & Restricted Articles What Items Are Prohibited on Site 8 What Items You Can Bring on Site 10 What Items Need Written Permission to be Allowed on Site 11 Revision 12 Section No 3 Smelter Safety Policy & Proceedings Smelter Occupational Health and Safety Policy 13 Hyper-Reactive Airways or Asthma 14 Who is responsible for safety at the Smelter 15 Safe Behaviour Observance 15 Safety Sampling 16 Duty of Care 16 Risk Management System 17 Incident Reporting 18 Near Miss Hazard Reporting 19 Revision 20 Section No 4 Alcohol PPE - Housekeeping & Smoking, Drugs, What Personal Protective Equipment [PPE] Must Be Worn at Work 21 General Housekeeping 22 No Smoking Policy 23 Alcohol and Other Drugs Policy 24 Revision 25 Section No 5 Emergencies, First Aid - PEO Emergency Procedures 26 The Plant Emergency Organisation [PEO] 27 How to Raise An Alarm 28 What to Do If You Hear An Alarm 29 Fires 30 Fire Extinguishers 31

7 What Are the Evacuation Procedures For the Smelter 32 First Aid Facilities 33 Injury Management and Rehabilitation 33 Revision 34 Section No 6 Signs Red 35 Blue 35 Yellow 36 Green 36 Revision 37 Section No 7 Safety For Vehicle Drivers & Pedestrians Vehicles on Site 38 Driving on Site 38 Vehicles being taken into Potline Buildings 40 Driving Around Mobile Plant and Equipment 41 Walking Around the Smelter 42 Parking 43 Revision 44 Section No 8 Workcover Authority Codes of Practice 45 Certificate of Competency 46 Revision 47 Section No 9 Equipment Safety Regulations Electrical Equipment Inspection Tags 48 Hazardous Substances 48 Cutting Implements 50 Magnetic Fields 51 Confined Spaces 52 Explosive Powered Tools 52 Gas Cylinders 53 Compressed Air 53 Lifting Equipment 54 Barricading 55 Revision 56 Section No 10 Authority to Work - Locks & Tags Authority to Operate 57 Authority to Work [Work Permits] 58 Lock-Out, Out of Service Tags, Caution Tags, Hazard Alert Notices 59 Revision 67 Section No 11 The Environment Environment Policy 68 What If Pollution Occurs Where I Am Working? 69 Reduce, Reuse and Recycle 70 Waste Disposal 70 Revision 71 Section No 12 Confidentiality & Information Protection of Information 72 Media Enquiries 72

8 INTRODUCTION : SAFETY AT THE SMELTER There are strict rules about safety which everybody must obey when entering and/or working at the Aluminium Smelter, Kurri Kurri. The rules are there to protect you as well as others working around you. The smelter follows all laws relating to Occupational Health and Safety. The requirements outlined in this booklet have been developed to help the Smelter provide a safe working environment for everyone on site. This book covers the general safety requirements for all persons coming onto the Smelter site. This includes all employees and all contractors. The first step required is for you to read and learn the contents of this book and then successfully undergo a competency based induction prior to entering and working on the site. All persons entering the site are also required, by OH&S law, to take reasonable care and comply with any requirement imposed in the interest of the health, safety and welfare of any persons on site (OHS Act Section 20) Any failure to obey and follow these rules at all times can result in You or others around you being harmed or suffering injuries. Your immediate removal from the site. You being fined and/or prosecuted by WorkCover. Disciplinary procedures being enforced. Y/HSE General/Inductions Page 1

9 SECTION 1 : THE INDUCTION SYSTEM The General Site Safety Induction All persons requiring entry to the Smelter site must participate in a safety induction and successfully undergo an assessment to demonstrate understanding of the safety rules covering the areas they need to be in and the work they are doing. This induction covers safety requirements and rules to enable persons to safely enter and work on the site unaccompanied in general areas only. Before contractors can undergo this general induction there must be a completed site entry and induction approval form. This is available from: 1. The Smelter Contract Supervisor, or 2. Your Team Co-ordinator This form requires the approval of the Smelter Managing Director or the appointed representative. After approval has been granted, a suitable time and date is to be organised for you to come to the site and do the induction. At the end of the induction you will be required to do an assessment in the form of a questionnaire. This assessment will comprise a number of critical questions which you must answer 100% correctly. The balance of questions you must get at least 80% correct. This general site induction is valid for 2 years. Employees will be subject to induction and periodic reassessment. Y/HSE General/Inductions Page 2

10 SECTION 1 : THE INDUCTION SYSTEM The Passport Book On successful completion of the assessment contractors will be issued a Smelter site passport book with a photo identity card. The photo identity card allows you to enter the site whilst you are authorised to be here. You must carry the photo identity card and passport with you at all times whilst on the site. Contractors - you may be required to show your photo identity card and passport at the main gate when you enter the plant and will have to produce it on request whilst on the site. Any other Smelter inductions or site training will be entered into your passport as and when you successfully complete them. The passport is your proof that you are permitted to be in the various areas or conducting certain work or operations. The stamps in the passport will give details of any expiry dates and when you will be required to undergo future reinductions or training sessions. Contractors - it is your responsibility to hand your photo identity card into the main gate at the end of the job. For employees, on successful completion of the assessment you will be given a photo identity card and your training records will be updated. You will still be required to undergo future re-inductions or training sessions. Y/HSE General/Inductions Page 3

11 SECTION 1 : THE INDUCTION SYSTEM VISITORS The inducted person is responsible for the visitor from the time they enter the gate until they exit the gate. There is a Smelter Visitor s Induction Brochure, which each visitor must read, follow and sign for, each and every time they come onto the site. This brochure details the safety rules, dress, personal protective equipment and how a visitor is to conduct themselves. The inducted person escorting the visitor is responsible for that visitor and will ensure the visitor knows and follows the directives in the brochure. Visitors to site will be required to wear a high visibility visitor vest in addition to the minimum standard PPE as detailed in Section 4. VISITOR Y/HSE General/Inductions Page 4

12 SECTION 1 : THE INDUCTION SYSTEM What the General Site Safety Induction Does not cover The General Site Safety Induction does not allow you to enter and work in areas such as - 1. Casting Plant 2. Potrooms 3. Carbon Plant 4. Switchyards 5. Confined Spaces 6. Restricted Areas Each of these areas require separate inductions and/or training sessions which can only be undertaken after successful completion of this general safety induction and if you have legitimate reasons and approval to enter and work in these other areas. Y/HSE General/Inductions Page 5

13 SECTION 1 : THE INDUCTION SYSTEM What Work The General Site Safety Induction Will Not Let You Do This induction does not allow you to do certain work or jobs for which you must have specific induction, training or authorization. These jobs could include such things as - Isolation procedures Excavations Confined spaces entry Entry to restricted areas Hot work Working at heights You must obtain information and approval, which may require a separate induction/training, before you undertake work or entry into other areas. See your Team Co-ordinator or the Smelter Contract Supervisor for more inform ation. Y/HSE General/Inductions Page 6

14 R E V I S I O N Points to Remember The general induction only allows you to enter and work unaccompanied in general areas at the Smelter. You must carry your passport with you at all times. Visitors must be accompanied at all times by an inducted person. The general induction does not allow you to do certain work or jobs for which you must have specific induction, training, authorisation. Self Test 1. Can you enter a confined space at the Smelter after you have completed the general induction without any other training or authorisation? Yes Π No Π 2. Can you enter ALL work areas unaccompanied after completion of this general site induction? Yes Π No Π 3. Who must a visitor be accompanied by at all times whilst on the Smelter? Y/HSE General/Inductions Page 7

15 SECTION 2 : PROHIBITED AND RESTRICTED ARTICLES What Items Are Prohibited On Site Due to safety issues, the following items are banned from the smelter site. 1 Glass bottles or jars 2 Cans 3 Cigarette lighters 4 Illicit or illegal drugs 5 Firearms and ammunition 7 Alcohol 6 Pets, animals 8 Open blade knives If any of the above items are found on site they must be reported to Ambulance/Security Officers at the main gate and an incident report raised. Y/HSE General/Inductions Page 8

16 SECTION 2 : PROHIBITED AND RESTRICTED ARTICLES If glass bottles and cans are inadvertently placed in scrap bins and fed into furnaces or pots, a major explosion may occur which could result in serious injury, damage or possibly death. If any of the above items are found on site they must be reported to the Ambulance/Security Officers at the main gate and an incident report raised. Y/HSE General/Inductions Page 9

17 SECTION 2 : PROHIBITED AND RESTRICTED ARTICLES What Items Can You Bring On Site The following items are acceptable at the Smelter site Examples of acceptable containers, which are classified as disposable or reusable. If a container is available at the site canteen then the style/type has been approved and it is acceptable for use on site. Plastic carbonated drink bottles are permitted in certain areas on site, and it is important that the following rules are adhered to regarding their use: 1. Departments will manage the carbonated drink containers within their areas; 2. The contents of plastic drink bottles can only be consumed in non-production areas or other areas authorized by the Department Manager; 3. The drink bottle must be completely empty prior to disposal; 4. The empty plastic drink bottle is to be disposed of by placing it in the blue plastic recycling bin located in the lunch room or office area. Y/HSE General/Inductions Page 10

18 SECTION 2 : PROHIBITED AND RESTRICTED ARTICLES What Items Need Written Permission To Be Allowed Written permission is required before the following items will be admitted on site. 1 Explosives and explosive powered tools 2 Metal ladders and scaffolding 3 All pressurised containers ie paint pressure packs, aerosol cans, etc 4 Hazardous substances - dangerous goods 5 Cameras For information on how to obtain written permission contact your - Smelter Contract Supervisor Team Co-ordinator Site Safety Co-ordinator Y/HSE General/Inductions Page 11

19 R E V I S I O N Points to Remember Items that are prohibited from The Smelter include - Glass bottles and jars Plastic bottles of similar shape to glass bottles Cigarette lighters Alcohol Illicit or illegal drugs Firearms and ammunition Pets and animals Items such as cardboard milk and juice containers are allowed at the Smelter but must be disposed of properly in rubbish bins provided. You need written permission first before the following items are allowed on site - Explosives and explosive powered tools Metal ladders and scaffolding All pressurised or aerosol containers Hazardous substances - dangerous goods Cameras Self Test 1. Can you bring a glass bottle of soft drink and a can of baked beans to the Smelter for your lunch? Yes Π No Π 2. What could happen if a glass bottle was put into a scrap bin at the Smelter? 1 An explosion may occur Π 2 Nothing Π 3. If you need to bring an aerosol can of spray paint or similar to the Smelter what must you obtain first? 1 A special sealed carry case Π 2 Written permission Π 3 Nothing if you do not leave it at the site Π Y/HSE General/Inductions Page 12

20 SECTION 3 : SMELTER SAFETY POLICY AND PROCEDURES Smelter Occupational Health and Safety The Smelter has an Occupational Health and Safety policy. This policy is to ensure Health and safety is an integral part of the business. All injuries and occupational illnesses are preventable. Management demonstrates leadership in safety. Everyone is responsible for safety. To continuously improve safety performance. Copies of the policy are displayed on site. If you would like a copy speak to your Team Co-ordinator or Smelter Representative. Consultation Employee involvement at all levels is critical for ensuring a safe workplace. Following consultation with all employees during August 2002, OHS Committees were selected as the primary means for consultation. There are five OHS Committees on site; Potrooms, Casting, Carbon, Technical Services and Administration. All committees are made up of employer and employee representation. Although OHS Committees are the primary means of consultation all personnel on site are required to draw their supervisor's or OHS representative's attention to any OHS concerns so the issue can be promptly addressed. Additional methods of consultation may be in the form of small group discussions, toolbox sessions or team meetings. Y/HSE General/Inductions Page 13

21 SECTION 3 : SMELTER SAFETY POLICY AND PROCEDURES Hyper- Reactive Airways or Asthma All contractors, their employees and subcontractors who have active asthma or who has a history of recent asthma will not be cleared to enter Hydro Aluminium Kurri Kurri. This is to ensure that people are not unnecessarily exposed to production processes which may affect this condition. A person, who has risk factors for hyperreactive airways disease, will need a clearance following a standard and appropriate respiratory assessment. A Respiratory Symptoms questionnaire must be completed prior to any work at Hydro Aluminium Kurri Kurri. The purpose of the questionnaire is to assist Hydro medical staff to assess whether a person may have a respiratory condition and for clearance to work at Hydro. Point to Remember Personnel who have active asthma or have a history of recent asthma will not be cleared to enter Hydro Aluminium. Y/HSE General/Inductions Page 14

22 SECTION 3 : SMELTER SAFETY POLICY AND PROCEDURES Who is Responsible For Safety At the Smelter Everyone working at the smelter is responsible for safety at the Smelter. The smelter must provide 1 Safe plant 2 Safe premises 3 Safe systems of work. You have a personal involvement in these things. You are responsible and required to carry out the following- Safe Behaviour Observance This means you must constantly consider What am I about to do? What could go wrong? What can I do to make it safer? You may also be asked the same questions by others around you. Y/HSE General/Inductions Page 15

23 SECTION 3 : SMELTER SAFETY POLICY AND PROCEDURES Safety Sampling Safety Sampling is one part of the safety system in operation at our plant. All employees and contractors are expected to be involved in the process. Safety Sampling is a regular check on: The equipment we use. The systems we work with. The behaviours we display at work. People from all levels in the organisation perform these checks, which are recorded on standard sampling sheets. The sheets define the standards which should be in place. You will be involved in Safety Sampling through other employees observing your work and by you observing and recording what you see. Your participation in this process will help to make our workplace a safe place to work. Duty Of Care The law and the Smelter requires everyone from you to the Managing Director to exercise duty of care when at work. There are different levels of responsibility for duty of care. The Smelter, through its management, must supply the safe place and systems of work. You must co-operate with the Management in implementing and carrying out these safe systems. This is done by you participating in the various safety programs, helping to identify hazards, following the rules and procedures set out and promptly reporting any problems with the systems. Y/HSE General/Inductions Page 16

24 SECTION 3 : SMELTER SAFETY POLICY AND PROCEDURES Risk Management System The Smelter has a workplace hazard identification, risk assessment and management program as a main tool for providing a safe place and safe systems of work. This is not only required by law. It is a common sense and logical step as a pro-active approach to safety in the workplace. The emphasis is to identify hazards before they can harm you and then, by a risk assessment process, either eliminate the hazard altogether or reduce any risks to acceptable levels. The four elements of this program are - 1 Hazard identification 2 Risk assessment of the hazard 3 Identifying and choosing the appropriate control for the hazard 4 Implementing the control and ensuring ongoing effectiveness in the workplace. Everyone at the Smelter whether you are an employee or contractor must participate in this program either by participating and assisting someone else doing a risk assessment. OR initiating and conducting a risk assessment yourself in consultation with others. Y/HSE General/Inductions Page 17

25 SECTION 3 : SMELTER SAFETY POLICY AND PROCEDURES Incident Reporting Everyone at the Smelter is required to promptly report all incidents at work. This includes any - Injury - no matter how small Any incident Any unsafe place or practice Any near miss By reporting near misses, unsafe places, unsafe equipment or unsafe practices, you will be helping to prevent future injuries occurring to yourself or others at the site. Report these occurrences to your Team Co-ordinator The Smelter Contract Supervisor The Smelter Site Safety Co-ordinator The Smelter has its own incident report form, which is available from any of the above people. Y/HSE General/Inductions Page 18

26 SECTION 3 : SMELTER SAFETY POLICY AND PROCEDURES Near Miss Hazard Reporting A near miss report is our best opportunity to be proactive and fix hazards before they reach their potential. If we act after an incident we are reactive. Use the system, the system will highlight actions and people responsible. It will allocate timeframes and escalate issues not closed out. Note: Location of Near Miss/Hazard Report If you have access to a computer enter report as below, if not locate a hard copy (from supervisor or site contact) and fill out hard copy, return to supervisor or site contact for completion on system. Select near miss / hazard (box up the top, near miss, hazard), Department and area: Dept manager will automatically receive report, Person reporting not compulsory, but it goes to the selected supervisor, Date: inserted automatically, Risk matrix High, medium and low (as a field). Click on likelihood and consequence to display descriptors, The team reporting the incident, Hazard: Drop down box, Describe the near miss/hazard, What actions have been taken to make it safe, Photo click browse to find file location and upload, Save report and review if correct, If correct click it will send and lock report. Y/HSE General/Inductions Page 19

27 R E V I S I O N Points to Remember You have a responsibility for safety whilst on the Smelter site. You must practice safe behaviour observance whilst on the Smelter site, where you must consider the following. 1. What am I about to do? 2. What could go wrong? 3. What can I do to make it safer? You must co-operate with management in implementing and following safe systems of work at the Smelter. Everyone at the Smelter, whether you are an employee or contractor must participate in the risk management system. ALL incidents and near misses/hazards no matter how big or small must be reported immediately or as soon as practically possible. Self Test 1 List the 3 things you must constantly consider for safe behaviour observance What incidents and near misses must you report immediately or as soon as possible? Y/HSE General/Inductions Page 20

28 SECTION 4 : PPE, HOUSEKEEPING AND SMOKING, DRUGS, ALCOHOL What Personal Protective Equipment PPE Must Be Worn at the Kurri Kurri Smelter All persons working on the site are required to wear the following minimum P.P.E. : Work clothing high visibility cotton drill shirt (190gm) with long sleeves, and cotton drill trousers, or overalls. Fully enclosed steel cap safety footwear. Australian Standards approved safety helmet, with reflective strips. Australian Standards approved safety glasses. Minimum standard PPE must be worn on site in all areas, unless clearly marked as an exception. This includes a green zone marked by white painted figures on the main entry walkways. A solid red line indicates that minimum PPE is required beyond that point. Specific P.P.E. must be worn in certain areas of the site and when performing certain tasks - local signs or your supervisor will indicate specific requirements. Individual department and specific work inductions and training will tell you what must be worn, where and when. Y/HSE General/Inductions Page 21

29 SECTION 4 : PPE, HOUSEKEEPING AND SMOKING, DRUGS, ALCOHOL General Housekeeping A clean and tidy site indicates a safer site. You must play your part in keeping the site neat and tidy with well organised work areas. Use the bins provided. Do not leave materials or equipment lying around. Clean up after yourself. Untidy work areas and practices: o significantly raise the risk of injury or incident. o are inefficient and may create fire and other hazards. Y/HSE General/Inductions Page 22

30 SECTION 4 : PPE, HOUSEKEEPING AND SMOKING, DRUGS, ALCOHOL No Smoking Policy As part of the Smelter OH&S policy to provide a safe and healthy environment for its employees, contractors and visitors - The Smelter is actively pursuing and promoting a smoke free work place to help reduce the effects of smoking and to protect others from passive smoking. The rules for tobacco and smoking at the Kurri Kurri site are: Sale of tobacco products prohibited on site Smoking is banned from:- All buildings on the site and All buildings at other locations under the Smelter Management s control All vehicles and mobile equipment All areas designated as non-smoking areas for fire and explosive risks. Smokers must dispose of their cigarette butts in the receptacles provided and not to discard them on the ground. Y/HSE General/Inductions Page 23

31 SECTION 4 : PPE, HOUSEKEEPING AND SMOKING, DRUGS, ALCOHOL Drug and Other Drugs Policy All individuals entering the Smelter are required to abide by the current Alcohol and Other Drugs Policy. Other drugs are defined as: Any prescription, non-prescription or illicit drugs, which may create a potential for impairment of work performance and therefore is likely to create a risk to an individual or others. Examples include, but are not limited to benzodiazepines, sympathomimetic amines, opiates, cannabis and cocaine. Under the policy 1. The sale, supply and manufacture of alcohol and other drugs is prohibited on Hydro Aluminium controlled sites. 2. The possession or consumption of alcohol and other drugs is prohibited on Hydro Aluminium controlled sites. 3. The operation of equipment, machinery and company vehicles whilst under the influence of alcohol and other drugs is also prohibited. Note: Individually prescribed medication is exempt from points (2) & (3) on the proviso that it is being taken in accordance with directions. The Alcohol and Other Drugs Policy may require you to undertake testing for alcohol and other drugs on a random, causal or post-incident basis. Refusal to comply with the requirements of the policy will result in disciplinary action, which may include being removed or banned from site. For additional information speak to your site supervisor or contact the Employee Relations Co-ordinator. Y/HSE General/Inductions Page 24

32 R E V I S I O N Points to Remember As a minimum, all persons coming onto the site must have and wear when necessary, or when local signs indicate - 1. Long sleeve and long trouser work clothing 2. Steel cap safety footwear 3. Safety helmet 4. Hearing protection 5. Safety glasses You must keep the site neat and tidy, clean up after you and put rubbish in bins provided. The Smelter has a no smoking policy which must be followed at all times. No alcohol or non-prescribed drugs are allowed on the site. Self Test 1 List the 5 items of dress/ppe you must have and wear when necessary What buildings are you allowed to smoke in? 3 Can you bring alcohol or non-prescribed drugs onto the site? Yes Π No Π Y/HSE General/Inductions Page 25

33 SECTION 5 : EMERGENCIES, FIRST AID - PEO There are emergency procedures and equipment on the Smelter site that are designed to save lives. These include the Emergency Response Plan Fire Suppression Systems Portable Fire Extinguishers First Aid Equipment Plant Emergency Organisation (PEO). They ensure that the plant and people are covered for any emergency 24 hours of every day in the year. Y/HSE General/Inductions Page 26

34 SECTION 5 : EMERGENCIES, FIRST AID - PEO The Plant Emergency Organisation (P EO) The PEO exist at the Smelter site to provide the first response to any threatening incident, accident or major disaster. The PEO crew is distinguishable by the Red safety helmets. You can contact the PEO by either Phoning on the EMERGENCY number or Using a two way radio or Operate the nearest break glass station. The PEO has access to an onsite Fire Engine, an Emergency Rescue 4WD vehicle and the onsite Ambulance. If any of the PEO vehicles sound their sirens, please move out of their path immediately. Y/HSE General/Inductions Page 27

35 SECTION 5 : EMERGENCIES, FIRST AID - PEO How to Raise an Alarm When there is an emergency in your immediate work area you can contact the Ambulance/Security Officer at the main gatehouse by either Calling 200 on any site phone or mobile or; Calling on any two way radio using Channel 3 or; Operate a break glass station. In the event that an emergency or major incident occurs it is important that everyone stays calm. Make sure that you, your work mates and anyone else nearby are not in any further danger. When reporting an emergency clearly communicate:- 1. The location. 2. Nature of the emergency. 3. Number of people affected. 4. Types of injuries. Y/HSE General/Inductions Page 28

36 SECTION 5 : EMERGENCIES, FIRST AID - PEO What You Do If You Hear An Alarm There are two plant alarms to advise you of any emergency. If the EMERGENCY is in the department you are in, the SIREN will sound ON-OFF-ON-OFF. There are three things that you must do if the emergency is in your department. 1. Look for danger to yourself. 2. If there is immediate danger, evacuate to the assembly area. 3. If there is no immediate danger, wait for instructions from either the PEO, your Emergency Warden or Team Co-ordinator or Smelter Contract Supervisor. If the EMERGENCY is outside the department you are in, the SIREN or bell will sound CONTINUOUSLY. There are two things that you must do if the emergency is outside your department. 1. Still look for danger to yourself. 2. Stay at your work area unless the PEO, Emergency Warden or your Team Co-ordinator/Smelter Contract Supervisor advises you otherwise. Y/HSE General/Inductions Page 29

37 SECTION 5 : EMERGENCIES, FIRST AID - PEO Fires The lighting of any fires on the Smelter site is strictly prohibited unless written permission has been obtained from the PEO Leader and adequate safeguards have been put in place. If a fire starts in the area you are working in you should do the following things; Raise the alarm, either o Dial 200 to advise the location of the fire o Call the Main Gatehouse on a twoway radio(channel 3) o Operate a Break Glass Station. Let people in the area know about the fire. When the PEO arrives, let them take over, as this is what they are trained for. Depending on the size and location of the fire you can elect to use an extinguisher to suppress the fire. However remember :- 1. This is generally limited to small localised fires. 2. Do not put yourself in immediate life threatening situations. 3. This is a judgement call and would depend on the circumstances at the time. Y/HSE General/Inductions Page 30

38 SECTION 5 : EMERGENCIES, FIRST AID - PEO Fire Extinguishers There are a number of fire extinguishers located throughout the Smelter site for various types of fires. Fire hydrants and hose reels are also located on various parts of the plant and must not be used for any purpose other than fighting fires. Y/HSE General/Inductions Page 31

39 SECTION 5 : EMERGENCIES, FIRST AID - PEO What are The Evacuation Procedures For the Smelter The order to evacuate all or part of the plant will be given by the PEO Leader. If an evacuation has been ordered, you must follow these rules :- 1. The evacuation of each section is under the control of the Emergency Warden for that section. Listen carefully to the instructions given by the Emergency Warden. When directed to evacuate, go to the nominated Assembly Area and wait for their instruction. 2. Remain calm at all times. DO NOT RUN. WALK BRISKLY 3. Do not return to your department or work area until you have been advised that you can by the Emergency Warden or the PEO SHOULD A MAJOR INCIDENT OCCUR, THE SITE AMBULANCE AND PLANT EMERGENCY CREW IS CALLED BY RINGING 200 ON ANY TELEPHONE EXTENSION. This phone number is written on every phone at the Smelter. Y/HSE General/Inductions Page 32

40 SECTION 5 : EMERGENCIES, FIRST AID - PEO First Aid Facil ities If you are injured at work, no matter how small the injury, you are required to report it to your Team Co-ordinator or Smelter Contract Supervisor and report immediately to the Medical Centre so you can receive appropriate treatment. The Medical Centre is located at the Main Gatehouse and is open 24 hours/day, 7 days/week. You can contact the Medical Centre during daywork on ext. 511 and after hours on ext Injury Management And Rehabilitation If you are injured while working on site, the Smelter has programs in place to manage your injury and provide rehabilitation (treatment, physiotherapy, modified work duties etc). The objective of the programs is to help you recover and return to full pre-injury status as soon as possible. The Smelter Worker's Compensation Co-ordinator can be contacted via the Medical Centre (extension 511). Rehabilitation and Worker s Compensation for contractors who suffer injuries while working on site are managed by the company they are employed by. Y/HSE General/Inductions Page 33

41 R E V I S I O N Points to Remember The Emergency Phone No. on site is 200. The Plant Emergency Organisation (PEO) provides first response to any threatening incident, accident or major disaster at the Smelter. To raise the alarm you can either 1. Use the phone 2. Call on a two way radio Channel 3 3. Operate a break glass station If you hear an alarm in the department or area you are in, you must - 1.Look for danger to yourself. 2. If there is immediate danger, evacuate to the assembly area. 3. If there is no immediate danger, wait and follow any instructions from the PEO, Emergency Warden or Team Co-ordinator/Smelter Contract Supervisor. You cannot light any fire on the Smelter without written permission from the PEO Leader. You can elect to use the appropriate fire extinguisher to contain small localised fires but do not put yourself in any life threatening situation. The PEO Leader is responsible to order the evacuation of all or part of the Plant. You must follow the instructions of the Emergency Warden for each section and not return to your department or work area until advised that you can by the Emergency Warden or the PEO. There is a medical centre located at the main gatehouse open 24 hours a day 7 days a week. Self Test 1 What is the on site emergency phone number? 2 Who is responsible to provide first response in any emergency at the Smelter? 3 What are the 3 ways of raising an alarm at the Smelter? What are the 3 things you must do if there is an alarm in your department or work area? Who must you get written permission from to light a fire on the site? 6 What 3 rules must you follow if an evacuation has been ordered? Y/HSE General/Inductions Page 34

42 SECTION 6 : SIGNS You must look for hazards because they are all around you. Look for signs, flags and barricades etc that warn you about hazards. Some of the Safety signs you will see at the Smelter site look like these. RED SAFETY SIGNS The RED safety signs show what you must NOT DO in that area. BLUE SAFETY SIGNS The BLUE safety signs tell you what kind of safety clothes and equipment is MANDATORY when entering a particular area. Y/HSE General/Inductions Page 35

43 SECTION 6 : SIGNS YELLOW SAFETY SIGNS The YELLOW safety signs show that there can be a danger or a risk to your health and you must proceed with caution in or around these items. GREEN SAFETY SIGNS The GREEN safety signs show you exits, safe assembly areas, first aid etc. Where there is work in progress, the appropriate warning signs, flashing lights and portable barricades must be displayed. If you need advice on what is required at your work site, contact your Team Coordinator or Smelter Contract Supervisor. Barricades are used to stop unauthorised entry into a dangerous area, and may be used on either warning or protective barriers. Unauthorised entry into barricaded areas is not permitted. Permission must be obtained from the person in charge prior to entering the barricaded area. Y/HSE General/Inductions Page 36

44 R E V I S I O N Points to Remember Constantly look for hazards which may affect you. Follow the directions displayed on all signs you see at the Smelter Where appropriate, warning signs, flashing lights, portable barricades must be displayed in addition to any fixed signs, barricades present at the Smelter. 1 What do RED signs mean? Self Test 2 What do BLUE signs mean? 3 What do YELLOW signs mean? 4 What do GREEN signs mean? Y/HSE General/Inductions Page 37

45 SECTION 7 : SAFETY FOR VEHICLES, DRIVERS AND PEDESTRIANS Vehicles On Site You are only allowed to drive on the Smelter site for work reasons. Permission from the Ambulance/Security Officer is required for access for your vehicles. Your vehicle is subject to inspection by the Ambulance/Security Officer. Driving On Site The musts for driving vehicles on the site are: - The maximum speed limit on roads on the Kurri Kurri Smelter site is 12kph unless otherwise signposted. You must also consider other conditions when you drive on the site, such as local work hazards, weather, mobile plant etc. As a driver, you must be appropriately licensed (An RTA learners permit is not acceptable). You and your passengers must wear seat belts (where fitted). You must follow all road signs. Y/HSE General/Inductions Page 38

46 SECTION 7 : SAFETY FOR VEHICLES, DRIVERS AND PEDESTRIANS Driving On Site You must wear safety glasses in your vehicles if the windows are wound down. You are not allowed to transport people or be transported yourself in the back of a truck or utility. Your vehicle is not permitted within any building without permission of the Team Coordinator in that area. When driving your vehicle you must avoid Hot Metal areas and give way to Molten Metal vehicles. Any load on your vehicle must be safely secured and loose loads must be secured when leaving the site. Children and pets are not allowed to enter the Smelter site. Y/HSE General/Inductions Page 39

47 SECTION 7 : SAFETY FOR VEHICLES, DRIVERS AND PEDESTRIANS Vehicles Being Taken Into Potline Buildings In the Potline Buildings it is possible to short circuit between a pot on one side of the building and a pot on the other side. If this happens, massive electrical arcing occurs that could have catastrophic consequences including injury and damage. High-risk vehicles are insulated to assist in reducing the risk of short-circuit. But it is possible that other non-insulated vehicles may need to be used in a Potline. The following rules apply: The driver must be Potroom inducted or under the control of a Potroom inducted person. Correct procedure must be used, or a Risk assessment must be undertaken before the vehicle can be used in a Potline building. All non-potroom vehicles carry the sign shown below as a reminder: Y/HSE General/Inductions Page 40

48 SECTION 7 : SAFETY FOR VEHICLES, DRIVERS AND PEDESTRIANS Driving Around Mobile Plant and Equipment There are three things for you to remember when driving around the site and you encounter mobile plant. STAY ALERT STAY AWAY BE PATIENT Y/HSE General/Inductions Page 41

49 SECTION 7 : SAFETY FOR VEHICLES, DRIVERS AND PEDESTRIANS Walking Around The Smelter When walking around the Smelter site always walk on the footpaths or walkways which are marked. Do not take short cuts. Running on the plant is strictly forbidden as well. Pedestrians must give way to vehicular traffic at all times and use marked crossings where provided when crossing the road. Always stay well clear of all mobile equipment like anode haulers, hot metal transport vehicles, forklifts etc. Often the driver does not have a clear view and may be unable to stop quickly in an emergency situation. When you have to approach moving mobile equipment Attract the attention of the driver Approach when you have been seen Do not approach from a blind spot Y/HSE General/Inductions Page 42

50 SECTION 7 : SAFETY FOR VEHICLES, DRIVERS AND PEDESTRIANS Parking Before you leave your vehicle check that you Parked in a place marked as a carpark Are not restricting traffic Are not behind or too close to mobile plan Y/HSE General/Inductions Page 43

51 R E V I S I O N Points to Remember You must have permission from the Smelter site security before you can bring your vehicle onto the site. Your vehicle is subject to inspection by the Smelter Ambulance/Security Officer. The maximum speed limit on roads at the Smelter is 12 KPH. Drivers and passengers must wear seat belts when fitted. You must follow and obey all road signs. You cannot drive a vehicle into any building without permission from the Team Co-ordinator in that area. Children and pets are not allowed to enter the Smelter. You must be very careful when you encounter any mobile plant when driving around the site, by - 1. staying alert 2. staying away from the mobile plant 3. being patient Pedestrians must give way to vehicular traffic at all times and use marked crossings where provided when crossing the road You must not run on the site and always walk on the footpaths or walkways. You can only park in areas marked as a car park and do not restrict other vehicles or mobile plant. Self Test 1 Do you need permission to drive your vehicle on the Smelter site? Yes Π No Π 2 What is the maximum speed limit on the Smelter roads? 3 You must wear safety glasses in a vehicle if the windows are wound down - Yes Π No Π 4 What must you do if you need to drive into a building on the Smelter? 5 Where can I park on the Smelter site? 6 Vehicles have the right of way over pedestrians at all times? Yes Π No Π Y/HSE General/Inductions Page 44

52 SECTION 8 : WORKCOVER AUTHORITY Codes Of Practice At the Smelter site rules and procedures exist, which are in place for the safety of you and your workmates and to ensure we produce aluminium efficiently. In addition the WorkCover Authority has rules for working safely. They apply to all worksites and there are some rules specific to the Smelter site. These rules cover such things as safe lifting methods, the correct use of harnesses and safety belts and working at heights. Y/HSE General/Inductions Page 45

53 SECTION 8 : WORKCOVER AUTHORITY Codes Of Practice The WorkCover Authority rules state that you must have a Certificate of Competency to do some jobs, for example: Scaffolders, Crane Drivers, Plant Operators, Riggers, Crane Chasers/Dogging, Explosive Power Tools. MUST BE ON SITE You must have your Certificates of Competency on you (your person or locker/bag) at all times when on the Smelter site. If you don t follow the rules set out by the Smelter or WorkCover you can be personally liable to a fine, court action or gaol. Y/HSE General/Inductions Page 46

54 R E V I S I O N Points to Remember In addition to the Smelter site specific safety rules and procedures - you must also follow all WorkCover Authority rules whilst on site. WorkCover require you to have a current certificate of competency to do some jobs or operate certain equipment. You must have the appropriate certificate available on the Smelter site. Self Test 1 Where must your current WorkCover certificate be when doing jobs or operating equipment requiring such certificates? 2 What could you be liable for if you don t follow the safety rules set out by the Smelter or WorkCover? Y/HSE General/Inductions Page 47

55 SECTION 9 : EQUIPMENT SAFETY REGULATIONS Electrical Equipment Inspection Tags When your work does not require you to approach or handle electrical equipment or cables, keep away from them. At all times, electrical equipment must be thought to be live and dangerous. Treat it with respect. All electrical tools, appliances, leads etc. must be inspected by a licensed electrician and have a current inspection tag attached to the equipment before you can use the equipment at the Smelter. No tag...no use. Hazardous Substances Working with or coming into contact with hazardous substances can be extremely dangerous to your health and well being. Hazardous substances can have an immediate effect on you or in some cases have a long term effect which is not immediately felt. Y/HSE General/Inductions Page 48

56 SECTION 9 : EQUIPMENT SAFETY REGULATIONS No hazardous substance can be brought into the Smelter without - 1 A current (within the last 5 years) Material Safety Data Sheet (M.S.D.S.) 2 The container being correctly labelled and readable. 3 A risk assessment for the specific use for which the hazardous substance is intended to be used. 4 Written authorisation from the Smelter's Site Safety Co-ordinator. The correct control measures, as required by the risk assessment, must be observed at all times when handling, storing and using hazardous substances. If decanting of hazardous substance from one container to another is required, you must ensure that the container the hazardous substance is being transferred into is made of material which will safely hold the substance. that the container the hazardous substance is being transferred into is correctly labeled Y/HSE General/Inductions Page 49

57 SECTION 9 : EQUIPMENT SAFETY REGULATIONS No residues or partially used containers of hazardous substances are to be left around the Smelter. Left over hazardous substances must be either removed from the site or disposed of correctly or stored on the site correctly Cutting Implements A spring loaded (self retracting) metal safety knife is the approved style for the Hydro site and is only to be used where there are no other alternatives. Persons who have identified they need to use a knife for activities on site, are required to complete a risk assessment and also seek approval from the relevant Hydro supervisor. Y/HSE General/Inductions Page 50

58 SECTION 9 : EQUIPMENT SAFETY REGULATIONS Magnetic Fields The potlines (and other areas on site) emit strong magnetic fields that may have an effect on people who have medical implants and/or heart pacemakers, as well as possible effects to unborn children of females during pregnancy. You must inform your Site Supervisor if you are likely to be affected by strong magnetic fields so necessary precautions can be taken. Magnetic fields in the potlines may affect: Analogue Watches Heart Pacemakers or other implanted electronic devices EFTPOS and Bankcards, Credit Cards etc These items should not be taken into the Potline area. Y/HSE General/Inductions Page 51

59 SECTION 9 : EQUIPMENT SAFETY REGULATIONS Confined Spaces There are a number of areas or jobs which are defined as work in a confined space. Specific safety and training requirements apply to these areas and are outlined in the Confined Spaces Manual. You will need to attend specific training if you are required to enter or work in, on or around confined spaces Explosive Power Tools If you are going to operate explosive powered tools on the Smelter site you must obtain an authorised work permit and written permission from the Site Safety Team first. They can be contacted on extension 652 or 235. Y/HSE General/Inductions Page 52

60 SECTION 9 : EQUIPMENT SAFETY REGULATIONS Gas Cylinders When you are working with or around gas cylinders, you need to take special precautions. Gas cylinders are not to be left free standing Secured so they cannot be accidentally knocked over Only lift one cylinder at a time Do not store cylinders in hot places or where sparks can reach them Oils and greases must not come into contact with compressed oxygen cylinders. When entering the plant with gas cylinders, you need a tag from the Ambulance/Security Officer for each cylinder you bring onto the plant. When you leave the plant with your cylinders, the tags are returned to the Ambulance/Security Officer. Welding Equipment All your gas cylinders must have current pressure test stamping as required by the WorkCover Authority and Australian Standards To reduce the risk of electric shocks from welding voltages all welders used on site shall be fitted with either: VRD (voltage reducing device), complying with AS1674 Compressed Air Trigger switch that opens the welding circuit unless it is closed, complying with AS1674 (typically MIG welders) Compressed air is used on the site for specific purposes but it can be a dangerous tool and you need to be careful using it in the workplace. Do not use compressed air to remove dust from clothing Do not direct a stream of compressed air at yourself or your workmates. Y/HSE General/Inductions Page 53