Title: Cluster 1: Work Safely and follow WHS Policies and Procedures

This course outlines the skills and knowledge required to work safely and follow WHS policies and procedures in the resources and infrastructure industries.

This unit is appropriate for those working in operational roles.

Licensing, legislative, regulatory and certification requirements that apply to this unit can vary between states, territories and industry sectors. Relevant information must be sourced prior to application of the unit.

The content is based on the unit of competency RIIWHS201D and covers 5 main elements:

1. Access and apply site safety procedures

2. Apply personal safety measures

3. Apply operational safety measures

4. Maintain personal wellbeing

5. Identify and report incidents

Access and Apply Site Safety Procedures

Housekeeping and How to Use this Material

If you are a first time user of online material

Welcome and we hope you enjoy the experience.

There are several units to go through and it will have various things to do and see. You can read through the material, scroll over the picture on the info symbol to get more information, listen to the audio and watch movies related to the topic. You then answer the questions and move to the next topic. You can come back at anytime. Have fun.

If you are participating in this course in a group on site please be aware of the following information

Location of the :

- Fire exits
- Emergency muster point
- Toilets
- Crib facilities
- Course duration
- Please put your mobile phones to silent
- Ask questions at any time

- Ask questions at any time

- Crib facilities
- Course duration
- Please put your mobile phones to silent

Inductions

Inductions are conducted at nearly every work place in Australia.  They are simple and effective way to welcome and distribute important information to new employees.

General Inductions relay information relating to;

- Camp/Village emergency muster points
- Camp/Village evacuation procedures, WHS issues, rules
- Company policies and procedures, restricted areas, etc
- Transportation times/locate conducted at nearly every work place in Australia.  A simple effective way to welcome and distribute important information to new employees.

Company policies and operations

- Mess, canteen and wet mess hours of operation
- Camp contact points, Medical centre location.

Inductions: Continue

Fitness for Work policy incorporates rules/procedures align with Australian standards including:

- Mandatory drug and alcohol testing.

These tests will also be requirements if you’re involved in:

- Blanket and random
- An incident
- Vehicular or mobile equipment accident
- Or if any person thinks that another person may be under the influence they have the Duty of Care to report this to their supervisor.

Site Inductions relay specific information relating to;

- Plant/Mine emergency muster points, evacuation procedures
- Site contact points, Medical centre locations
- Restricted areas, licensing requirements, etc

Inductions: Continue

Area/Plant Specific Inductions relay information relating to;

- Sections within process plant
- Emergency facilities/procedures, plant muster points
- Safety showers, eye wash stations, fire fighting equipment
- Rules, process plant contacts, crib facilities, telephones
- Energy control isolation's/Permit to Work systems use
- Site training, licensing/ticketing
- Site plans/signage contains information of road rules, specific locations, PPE needs, entry restrictions, hazards, etc.

NEVER assume one site’s systems will be the same as another. If unsure, ask your supervisor.

Site Information

Specific rules including signs on the work site can communication for examples as shown;

Crib rooms, offices, buildings, noticeboards, sign boards in the plant are used to identify specific locations, transport rules, safety requirements and hazardous areas.

Can you identify any of these signs and symbols?

Legal Requirements

- OHS law minimizes risk by enforcing safe systems and practices on worksites.
- Employers and Employees have a Duty of Care under the OH&S and Mining Act.
- Duty of Care is a two-way contract between the employer and the employee.

Duty of Care legal requirements (Section 19 WSH Act, Section 9 MSI Act) for Employers include:

- Provide and maintain safe workplaces, plant and work procedures
- Provide safe systems of work
- Provide correct PPE to perform tasks safely
- Provide employees with adequate information, instruction, training and supervision
- Report all serious workplace injuries to the relevant authorities

Duty of Care legal requirements (Section 20 WSH Act, Section 10 MSI Act) for Employees include:

- Work in a safe manner at all times
- Make sure their actions do not create hazards to the health and safety of those in their area
- Comply with all policies, procedures and standards
- Use all PPE provided
- Report any hazards

Legal Requirements: Continue

Duty of Care legal requirements (Section 20 WSH Act, Section 10 MSI Act) for Employees include:

- Work in a safe manner at all times
- Make sure their actions do not create hazards to the health and safety of those in their area
- Comply with all policies, procedures and standards
- Use all PPE provided
- Report any hazards

Safety Responsibilities

Examples of Safety Compliance Documentation.

1. Safety Health Environmental Management Plan - outlines corporate management plan for ensuring compliance to legislative, company and client WHS policies/procedures. https://www.legislation.qld.gov.au/legisltn/current/w/workhsa11.pdf
2. Policies/Procedures - including drug/alcohol, reline quality, fatigue management, equal employment opportunities, employee assistance, employee conduct, incident reporting.
3. Reline Management Plan - provides an informative systematic approach to safely and efficiently managing all relines, whilst maintaining compliance to WHS law.
4. Job Safety Analysis - are used to break tasks down into individual steps, then identify each steps hazards and put adequate controls in place to minimise their risks so the task can be performed safely.

Safety Responsibilities - Communication Methods

- SDS’s. Material Safety Data Sheets outline properties, hazards, handling methods, storage needs, disposal needs, PPE requirements, etc. for chemicals used on site.
- Checklists, Inspections etc. all provide a tool for ensuring vehicles, equipment, work comply to set standards/condition. These standards have been developed to align with Laws, Regulations and Acts.
- Reports, Meeting minutes, Log books all provide a reporting method. Recording and reporting of individual events is required for legislative, insurance and quality control needs.
- Work sites also use the same type of documentation as listed above, as well as permits and certificates. This documentation has basically the same information and requirements, along with the need to meet legislative, insurance and site quality control needs.

Site Safety Systems

Site Safety system can include a number of tasks and equipment , for example Isolation can include:

- Removing a breaker, fuse, etc.
- Removing a section of pipe work.
- Isolating air supply that operates valve, etc.
- Physically locking a gear lever in position where it can’t activate.
- Removing a valve or part of equipment to break flow.

Any type isolation can be used but it must be locked by a qualified person and tested as emitting zero energy.

Permit Types

Permit to Work Systems are used for a number of reasons:

- Tool to verify equipment is safe to work on.
- Form part of the hazard control for specialised tasks.
- Allow the area personnel to know who is in their area working.
- Can be utilised to ensure all personnel are removed from the area in case of an emergency.

Important Rule for Permits – They are only valid as long as the scope of work remains the same. If the scope of work changes the permit must be cancelled and a new one sourced.

Types of permits & use

Types of Permits

Types of permits |
Types of permits | Use on mine sites
Safe Work Permit | Needed to perform all tasks on site by Contractor
Master Isolation Permit | Used on some sites to ensure large multi isolation equipment is isolated correctly
Confined Space Isolation Permit | Used on some sites to ensure confined spaces are isolated correctly
Confined Space Entry Permit | Used to authorise safe confined space entry
Radiation Clearance Certificate | Used on some sites to ensure safe radiation levels before work can commence
Gas Clearance Certificate | Used to ensure safe atmospheric conditions in the work area. (Normally confined space)
Working at Height Permit | Used to ensure working at heights work is performed using a safe method
Hot Work Permit | Used for all hot work to ensure safe conditions before, during and after hot work

Types of permits & use: Continue

Types of permits | Use on mine sites
Testing Permit | Used to test recently repaired equipment before being brought back online. Sometimes used for mill inching.
Inching Permit | Used specifically to inch mills during relines to ensure safe method of work.
Excavation Permit Used | to enable excavations to occur without coming into contact with buried electrical cables or other materials.

Reline Completion

- All permits and/or clearance certificates must be signed off at completion of reline.
- Personal danger tags and padlocks need to be removed from isolation lockbox points every time we leave the mill area, and before leaving site every shift.
- Do not be the cause of a delay by leaving your danger tag/lock on when you leave the work site. Always remove your tag, tear the eyelet from the tag, and dispose of it correctly in a rubbish bin.

Signage Types and Meanings

Hazard - "Danger"

Colour: A yellow triangle with a black border and black symbol.

Purpose: To warn of any type of hazard.

Meaning: Danger | Hazard | Caution | Beware | Careful

Safe Condition - "Safety"

Colour: A green oblong or square with a white symbol or text.

Purpose: To provide information about safe conditions.

Meaning: The safe way | Where to go in emergencies | First aid

Mandatory

Colour: A blue circle with a white symbol.

Purpose: Indicates that a specific course of action must be taken.

Meaning: Obey | You must | Carry out instructions shown | Do

Mandatory

Colour: A blue circle with a white symbol.

Purpose: Indicates that a specific course of action must be taken.

Meaning: Obey | You must | Carry out instructions shown | Do

Prohibition - "Stop!"

Colour: A red circular band with a diagonal cross bar on a white background; the symbol within the circle to be black.

Purpose: To indicate that a certain behaviour is prohibited.

Meaning: Stop | Do not | You must not

Mandatory: Continue

Fire Equipment - "Fire"

Colour: A red oblong or square with a white symbol.

Purpose: To describe the location of firefighting equipment.

Meaning: Location of fire fighting equipment | Type of fire fighting equipment

Safety Data Sheet

When handling chemicals or other dangerous goods read the relevant Safety Data Sheet before commencing SDS cover:

- Health hazards
- Precautions
- PPE required
- First aid procedures
- Safe handling of the product
- Emergency procedures
- Physical and chemical properties
- Transportation/Movement method
- Safe disposal techniques
- Environmental concerns

- Safe disposal techniques
- Environmental concerns

Safety Data Sheet: Continue

It is important to know:

- where your SDS are kept
- Understand site emergency procedures, and contact details.
- Know the chemical you are using
- Know the first aid treatment
- Know the location of eye wash stations/showers
- Know correct disposal of containers
- Be aware of proper use and storage of the chemical
- Labelling must be used when decanting chemicals

Housekeeping

Housekeeping forms an important part of relining. It consists of;

- Administrative, Legislative, Site and Company requirements
- Standard tool and rubbish removal

- Relines generate a lot of disposable material which can become hazards
- Housekeeping in the work area should be performed BEFORE, DURING AND AFTER the reline.

Below is a video example of good housekeeping during a mill reline, all steel cups washers being stored neatly in buckets, air hoses rolled up when not in use, nuts stacked against the kickboard.

Housekeeping: Continue

Housekeeping should include:

- Replacing all equipment safety guarding
- Removal of hoses, cables, debris and tools
- Follow site environmental procedures for waste/rubbish disposal. Consider material segregation systems.
- Complete post reline inspection of all equipment used for defects. (Follow defective tools method).
- Clean work area, pack up/store equipment and tools in correct locations.
- Check work area for potential hazards that may have been created.
- Notify appropriate person of reline completion to minimise delays in production
- Review related Job Safety Analysis (JSA) and Safe Work Procedures as per the continuous improvement policy so that we perform all tasks in the safest manner possible.

Environment

You are unable to comply with your site requirements if you are unaware of those specific environment processes.  You have a responsibility to create a safe working culture and you are the face and representative of Maxitool on site Each site is different, don't assume you already know.  Enure you work in accordance with these

- Legislative requirements
- Relevant Australian Standards
- WHS and Environmental guidelines
- Policies/Procedures
- Individual site Policies/Procedures

Areas that covered in the WHS ACT

Here is a list of some of the areas that are covered in the WHS Act:

Items covered in the WHS Act include: | Workplace Environment and Safety
Hazardous Materials and Substances | Workplace to have SDS's, Dangerous goods register, Segregation methods, Health surveillance system, Licences
Hazard Control | Workplace to have risk management system, (JSA, Take 5, RTHA, Risk assessments/controls, Hazops, Hazmat, Hazchem)
Location of Medical Centre/First Aid equipment/post | Need to be clearly sign posted. Communication process (Inductions)
Use of Fire Fighting Equipment | Workplace to have adequate/sufficient fire fighting equipment. Personnel trained to use. Emergency response strategies. Procedures/Inspections.

Reflection - Drag and Drop

Reflection: Here's a Refresh on Signage Types and Meanings. Match the Sign Type to the Sign Purpose.

Match Sign Type & Its Meaning

- To Warn of any type of hazard
- To provide information about safe conditions.
- Indicates that a specific course of action must be taken.
Q: Danger
A: To Warn of any type of hazard
Q: Safety
A: To provide information about safe conditions.
Q: Obey
A: Indicates that a specific course of action must be taken.

Reflection - True/False

Read the following statements and identify if they are True or False:

Read the following statements and identify if they are True or False

Q: Employers shall, under WHS and Mining ACT, provide employees with adequate information, instruction, training and supervision.
A: true

Q: Employees under WHS and Mining ACT shall make sure their actions do not create hazards to the health and safety of those in their area by working in a safe manner at all times.
A: true

Reflection - True/False

Q: An energy source does not include the energy that equipment can store
A: false

Q: The mill is an example of an energy source found on a mine site and must be treated as a possible source of a hazard at all times
A: true

Reflection - Multiple Choice

Which ways

Q: What Ways That You Can Adhere to WHS Requirements for the Workplace Environment?
- Adhere to site Energy Control Isolations (ECI) and Permit to Work (PTW) systems, Review and then sign onto the JSA to ensure you understnad the hazards and controls, and that it is still relevant to the job. (correct)
- Work in a safe manner at all times, make sure their actions do not create hazards to the health and safety of those in their area. (correct)
- Follow all safety instructions, Use all PPE provided and report any hazards. (correct)
Feedback (0 to 99%): Try again.
Feedback (100 to 100%): Well done!

Apply Personal Safety Measures

Tooling and Job Safety

General Safety Tips

Always follow correct procedures to minimise risk of injury and/or damage.  These procedures are written to keep you safe, short cuts are a quick path to injury.  Most procedures and processes will identify the safety equipment including PPE that should be used to complete the task.

Tooling and Job Safety: Continue

Here are some examples of statements that may be used to identify safety processes:

- All personnel must be outside of mill BEFORE a LRT starts to knock bolts in.
- Pedestrians are to keep well clear of moving equipment.
- A barricade must be erected around the area where the equipment such as cranes, forklifts and skid steers are operating, to prohibit unauthorised access to the area.
- Steel fragments breaking away from the moil of the Jackhammer may cause injury to the Skid steer operator, or any other personnel working in the vicinity.
- All spills (including hydraulic) shall be contained, cleaned up and reported as soon as practical to minimise environmental damage.
- All personnel working on the reline must place their personal danger tags and padlocks onto the Mill lockbox that is being relined.

Select and Wear Personal Protective Equipment (PPE)

What PPE is needed?

To identify the correct PPE required you need to :

- Read/Review the JSA /SWP
- Read the Instruction manual
- Look for signage in the work place
- Read the chemical SDS
- Ask your supervisor

Not wearing PPE, or wearing incorrect PPE can greatly impact on type and severity of injury.

PPE Requirements

Standard work sites minimum PPE requirements:

- Long Sleeve Shirt and Pants
- Safety footwear
- Safety Eye Wear

Mine sites minimum PPE requirements are as above plus:

- Hard hat.
- High visibility clothing /vest.

WH&S Regulations state:  https://www.legislation.qld.gov.au/legisltn/current/w/workhsa11.pdf

- An employer’s Duty of Care is to supply PPE to employees.
- An employee’s Duty of Care is to wear it, look after it, replace and report faulty PPE.

Legally Compliant and Safe Fall-Arrest PPE

Fall arrest PPE is to be worn wherever risk of falling from one level to another exists, or if a JSA/SWP/Risk assessment recommends. Working at Heights fall arrest systems shall comply with AS 1891.1.2.3.4 .

Legally Compliant and Safe Fall-Arrest PPE: Continue

Anchorage points used to attach safety harness systems shall comply with AS2865.

WHS Act identifies the following working at height requirements:

https://www.legislation.qld.gov.au/legisltn/current/w/workhsa11.pdf

- Only trained personnel should use safety harness systems
- Handrails are not suitable as anchor points.
- Anchorage points used should be located as high as equipment permits to minimise the risk of a free fall exceeding the design capacity of the fall arrest system.
- It is dangerous to work above the point of anchorage.
- A safety harness must be connected to a lanyard with a built in shock absorber; or a self – retracting lanyard
- There should be a visual inspection of all equipment prior to being used.

Manual Handling

Many injuries result from poor manual handling: (Back injuries etc.)

- Think about the task and plan it
- Can mechanical means be used
- Can help be given by others?
- Is the path clear?
- Are correct lifting techniques being used?
- STOP. Take five and think about the task!

- Protect your back
- Warm up cold muscles thoroughly before engaging in any manual work
- Lift and carry heavy loads correctly, by keeping the load close to the body and lifting with the thigh muscles or get help to lift or carry a heavy load whenever possible, using another worker or appropriate mechanical aids

Manual Handling: Continue

- Never attempt to carry or lift loads in excess of the recommended maximum limit for one person
- Maintain correct posture and the natural curves of the spine
- Organise the work area to reduce the amount of bending, twisting and stretching required.

The 7 "L's" of Lifting

The 7 “L’s” of Lifting

Lifting steps

1. Visualise Your Lift: Plan how you are going to perform the lift, where you are carrying the load and how you are going to put the load down.

2. Load: Check the load before you lift.

3. Legs

- Lift with you legs, not your back.
- Your large leg muscles are made for lifting and squatting.
- Your back muscles are too long and thin to be used for lifting.

The 7 "L's" of Lifting: Continue

4. Lungs

- Exhale when you do something.
- Before lifting the load tighten your abdominal muscles.
- Breath out through tightened lips as you lift.

5. Low Back

- Do not slouch your shoulders.
- Maintain the hollow of your lower back.
- Keep your upper back straight throughout the lift.

6. Lever Arm

- Keep the load close to your body.
- The closer the load is to your body the less it weighs.
- Spread you legs apart and move the load as close to you as possible.

7. Look Up

- Look up just before your lift.
- Your body follows the posture of your neck and head, so looking up will keep your back aligned correctly.
- Looking down will slouch your back.

7. Look Up

- Look up just before your lift.
- Your body follows the posture of your neck and head, so looking up will keep your back aligned correctly.
- Looking down will slouch your back.

Lifting Slings

Used for slinging any equipment required to be lifted for a mill reline.

- Lifting slings should be inspected before use
- Ensure you have the correct slings to lift the required weight
- Damaged slings should be tagged OUT OF SERVICE and not used. Destroy if possible.
- Keep synthetic slings away from hot work and hydrocarbons/chemicals.
- Follow correct lifting procedures.
- ONLY trained, competent and licensed Crane Operators / Dogmen / Riggers, or someone under their DIRECT control should inspect, or use lifting equipment.

Apply Safe Manual Handling Procedures

Here is a short clip of Gavin and Darryl on site, watch the clip to see how they go with moving a piece of equipment.

It is important to apply safe lifting and manual handling techniques.  Also notice Gavin and Darryl have selected, are wearing and caring for personal protective equipment for all activities that required personal protective equipment.

Reflection: Single Choice

Reflection

Q: What Part Does WHS Law Play Relating to the Workplace Environment?
- It minimises risk by enforcing safe systems and practices on work sites. (correct)
- It is the reason you have too much paper work to complete

Reflection: Multiple Choice

Q: Which Methods Can Identify What PPE to Wear for a Specific Task on a Mine Site?
- Read/Review the JSA and SWP for the task (correct)
- Read the Instruction manual (correct)
- Look for signage in the work place (correct)
- Read the chemical SDS (correct)
- Ask your supervisor. (correct)
- None of the above

Apply Operational Safety Measures

Inching the Mill

When the mill is to be inched for accessing the next mill linings, a safe efficient work method is to be followed, to eliminate risk of injury, and to minimise risk of production delays.

Before inching mill, the Pre-inching inspection check sheet need to be completed.

Method includes:

- Effective communication between reline and production teams so all personnel are ready to remove tags/locks when required.
- Final check that all linings are tight for inching.
- Confirmation that internal personnel and tools are clear and safe.
- Final external check that personnel, tools, equipment all clear of mill.
- PTW/CSEP suspension/cancellation confirmed.
- De-isolation/ Inching of mill.
- Re-isolation/ Pre-shutdown entry inspection.
- Resumption of PTW/CSEP/ replacement of tags/locks.
- Reline continuation.

- Re-isolation/ Pre-shutdown entry inspection.
- Resumption of PTW/CSEP/ replacement of tags/locks.
- Reline continuation.

Mill Entry Procedure

Before entering Mill you should:

- Conduct a thorough internal inspection

Confirm that mill is SAFE to enter check for:

- hazards (hung up debris/rocks/mill balls, loose/cracked linings before entry
- A safe action plan can then be implemented to control these hazards.
- Complete and sign the Pre-Mill Entry Inspection check sheet.
Each person should ALWAYS visually confirm the mill ceiling is clear of hung up, loose debris or cracked liners before entering.
- Before starting tasks, step back.
- Assess the job at the job front.
- Perform a Take 5/Real Time Hazard analysis.
- Consider new hazards that could be created, environmental hazards/ other tasks that may impact or be impacted on, changed conditions or equipment.

- Consider new hazards that could be created, environmental hazards/ other tasks that may impact or be impacted on, changed conditions or equipment.

Risk Management

How do you work out the risk of a situation?

Consider this example of a skate boarder goes down a hill, what is the task?, what is the incident that could occur? What's the likely hood an incident will occur? .  Look at the JSEA and think of what you would put in each column of the form as evidence of conducting the risk assessment on the situation.  Try and consider the example without the 'drilled in' knowledge of safety you may already have without knowing.

- Once identified, a hazard, needs assessing for chance of causing injury, harm or loss
- Identifying the possible consequence of a hazard, as well as the likelihood of the hazard resulting in injury, harm or damage can assist in highlighting the controls needed to be put in place to reduce the risk
- Hazard Risk is reduced/managed by using adequate controls.

Here is another example

Example: Knocking mill bolts through shell linings

- Reduction of Risk – Use Hierarchy of Controls
- Risk is reduced by using controls.

MOST EFFECTIVE SAFETY PROCESS

- Don’t do the task unless it must be done.  If it must be done then go through the hierarchy of controls.

Example of risk management

Here is another example

Example: Knocking mill bolts through shell linings

- Reduction of Risk – Use Hierarchy of Controls
- Risk is reduced by using controls.

MOST EFFECTIVE SAFETY PROCESS

- Don’t do the task unless it must be done.  If it must be done then go through the hierarchy of controls.

Risk Management Matrix

Ranges and limits - DAM STATISTICS!

There are a lot of ranges and limits to be considered when managing risk.  It isn't enough to just identify that there is a risk you have to link the risk to a level of risks.  There are statistical analysis ( scary I know but lets walk through it) to assist if a task or a job is a low or high risk and a low or high consequence regarding danger to a number of areas, people, environment, equipment , business.  These can be considered in injury levels, quantity levels and monetary terms .  Look at the tables below to links these together with tasks that can take place on a mine site.

Risk Management Matrix: Continue

Risk Management Matrix: Continue

Risk Rating Sequence

1. Identify most probable consequence
2. Determine most probable likelihood
3. Align above two outcomes on table to get risk rating
4. Follow recommended controls table
5. Repeat risk assessment after controls to determine reduction of risk and adequacy of controls

Tasks must not be performed if risk is still high or extreme after controls in place. More controls are needed.

Communication

- During a reline, as you would be well aware, knowing what to do and when to do it, can contribute to the success or failure of the reline. Effective communication plays a part in all relines, to ensure tasks are performed when required, and more importantly to ensure safety issues encountered are known by all reline team members.
- Clear and precise communication is critical between all reliners inside and outside the mill to minimise risk and delays. Knowing when to rattle up bolts, when to bring linings in, when to take linings out, which linings are required, when to undo bolts, move the liner handler, and move equipment with forklift, all enable the reline to run safely and efficiently.

Tooling and Job Safety

- A vast array of tools are needed to safely perform a mill reline in the least amount of time.
- These tools can be electric, hydraulic, pneumatic, hand powered, or even a combination of these.
- They all make the job easier and in most cases safer, but if used incorrectly or misused can result in injuries, damage to equipment and even delays to the job.
- Ensure that the correct tool is always used for the relevant task to minimise all risks.
- Some of the tools used, are identified and briefly explained in the following slides.
- For all tools being used, and for any part of the reline being undertaken, you should whenever possible read and review the Safe Work procedure (SWP) for the tool and/or task.

Take part and know your responsibility for your safety and others

Tag and test the equipment and ensure it is the correct tag before using the equipment.

- As well as reviewing the Safe Work procedure SWP, always perform a Take 5/Real Time Hazard Analysis before commencing any task during a reline to consider and control hazards.
- By completing these pre-task steps, it will minimise the chance of new or changed hazards from contributing to incidents.
- If no SWP is available, then a JSA must be conducted to control hazards.

Emergency Evacuation Procedure

When emergency evacuation alarms activate;

- Leave your area quickly. (Make equipment safe if possible to do so)
- Proceed to designated muster point
- Stay at the muster point and await further instructions
- Do not re-enter the building / area
- If you see other work mates along the way you must inform them of the emergency

Watch this video of what not to do:

Emergency Procedure

For all emergencies on site call the relevant emergency phone number and provide the following information:

1. Your name
2. Location of accident
3. Nature of emergency i.e. Fire
4. Number of casualties

DO NOT HANG UP THE PHONE OR LEAVE THE RADIO UNTIL TOLD TO DO SO.

If necessary position people by road side etc. to direct help to emergency site.

- Head to the Muster point as quick and safely as possible for more instructions.

First Aid

Upon arriving at the plant find out where the onsite Medical facilities are located and any special rules required for use. All injuries need to be reported as soon as practical to your supervisor:

First Aid Injuries on site could include:

- Snake/Spider bite
- Heat stress
- Strains, sprains, cuts
- Broken bones
- Major accidents

Fire Fighting

- Fire prevention is safer than fire fighting.
- If a fire is identified, only attempt to extinguish it if you are trained to do so, and feel safe to do it.
- Never attempt to fight a fire by standing down wind of it.
- Never use water on an electrical fire.
- All personnel must exit a confined space before activating a fire extinguisher inside of it, as toxic fumes may accumulate.

- Never return a used fire extinguisher to its storage position. Replace it with a fully charged extinguisher, and report the use.
- Check the extinguishers in your work area before you commence a task to ensure they are fully charged and have a current stamp.
- All fires on mine sites must be reported to WHS department, site WHS department and to the relevant governing authority.

Fire Prevention

TO HELP PREVENT A FIRE FROM OCCURING

- Obey no smoking signs
- Maintain good housekeeping (clean away excess rubbish)
- Store flammables away from the heat and ignition
- Store chemicals in correct locations
- Ensure electrical equipment is in good order and inspected regularly.
- Always keep fire extinguishers in an easily accessible location
- Look for Hazchem signs in front of building for Information of building contents

Portable Fire Extinguisher Guide

Safety Responsibilities

- It is everyone’s Duty of Care to ensure a safe workplace is maintained, both for themselves and for others.
- Accepting safety breaches from ourselves or our workmates, means we are as much a cause of someone being injured from this as the actual person is.
- We are liable if we ignore hazardous events that lead to incidents or accidents. - for example - All personnel MUST be outside of mill before LRT is to be operated. Being struck by a dislodged bolt or shard of steel could result in serious injury or worse.
- Safe Work Procedures provide a method for performing a specific task, that has been assessed as the safest and most efficient way of completing it.
- Site specific Work Instruction’s outline the reline from initial contact to post reline reporting and invoicing. These include all major safety considerations, expectations and guides to relevant safety documentation needed.

Remeber:

Remember:
- All employees required to operate industrial equipment as described in the “National Occupational Health and Safety Certification Standard for Users and Operators of Industrial Equipment” shall have been trained and certified in accordance with the standard.
- Follow correct Energy Control Isolation and Permit to Work systems.
- Follow correct operational procedure.
- All spills (including hydraulic) shall be contained, cleaned up and reported as soon as practical to minimise environmental damage

Safe Method for Defective Tools

Remove defective tool from the work area as soon as possible. (To minimise risk of reuse)

- Place an out of service tag on the tool with all relevant information ensure your writing is clear and eligible.
- Inform your supervisor.
- As soon as practical create a works request to have tool serviced/repaired.
- Organise for a replacement tool.
- Tools are not to be used until repaired by a competent person and the out of service tag is removed.

Example

If it is a lifting sling, destroy it to prevent re-use.

Routine Maintenance

- All tooling requires some type of regular maintenance to keep it in safe working condition, and to ensure it can perform its required task efficiently.

- This maintenance can include: Sharpening, greasing, degreasing, cleaning, drying, lubricating, inspecting for faults/defects, correct storage, purging of moisture, replacing renewable parts (eg: filters), tagging out of service, etc.

To determine the correct routine maintenance to perform, and the regularity of such maintenance, for a specific piece of tooling:

- Read the Instruction manual for the tool
- Read the SWP for the tool or task that the tool is used for
- Read the inspection check sheet / log sheet
- Read the pre-start checklist
- Contact the manufacturer
- Ask your supervisor.

- Ask your supervisor.

After use

After use, complete the following:

- Check all tools/equipment for defects and/or faults.
- Follow defective tools method if required.
- Wipe clean all tools/equipment as practical.
- Lubricate tools/equipment lightly.
- Store in correct location as specified.
- Enter work requests for maintenance or servicing as required.
- Complete any tooling documentation.

Reline Completion

- Post reline housekeeping is very important as it removes hazards, shows a good work ethic, and identifies professionalism.
- Administrative duties during relines are as important as manual duties.
- They ensure legislative, site and company needs are met.
- New safety implementations/laws, continuous improvement, quality control needs are met
- Ensure we finalise all documentation correctly

Energy Sources

Energy Control Isolations are isolations used to remove/isolate the energy at its source to stop it reaching the work area.  These can be performed by any of the following:

- Opening circuit breaker/locking open.
- Closing valves/chaining or locking shut
- Opening valves/chaining or locking open
- Inserting a blank or spade into a pipeline to stop flow.

Site Based Energy Control Isolations and Permit to Work Systems:

- Systems used to protect personnel from energy sources whilst working on equipment.
- What are energy sources? – Any equipment that can store and/or release energy.

Examples of energy sources on a process plant

Conveyors | Mills
Crushers | Pumps
Pipelines | Tanks
Vehicles | Hydro-cyclones
Compressors | Gas bottles
Electrical units | Engines
Pressure vessels |

Isolation - Legislation Compliance

Legislative (WHS), site and company requirements for working safely must be followed when entering any mill: https://www.legislation.qld.gov.au/legisltn/current/w/workhsa11.pdf

- Adhere to site Energy Control Isolations (ECI) and Permit to Work (PTW) systems
- Review and then sign onto the JSA to ensure you understand the hazards and controls, and that it is still relevant to the job
- Advise the Confined Space sentry before you enter
- Energy control isolations/Permit to Work system requirements must be completed before commencing any mill relining task.

Isolation - Legislation Compliance Continue

- Isolations need to be performed and the equipment tested, to confirm as zero energy.
- Personnel are not to perform any isolations, unless trained and authorised to do so by the site manager
- Personal danger tags /padlocks to be installed on correct isolation lockbox points.
- Permit to work, Hot work permit, Confined space entry permit, Working at height permit, Radiation permit, Gas clearance certificate, etc. to be completed and authorised. (As required)

Isolation and Tagging

Personal Danger Tag and Padlock

- To be placed on all equipment prior to repair /maintenance, including relines
- All equipment that stores energy needs to be isolated/tagged by qualified personnel.
- Never work under another persons danger tag or remove another persons tag.
- Danger tags can only be removed by the person who has signed the tag.
- Remove your danger tag after you have completed the repairs
- Never operate equipment that has a personal danger tag attached

Isolation and Tagging: Continue

Only qualified personnel who work for the main mining company shall isolate equipment. They are trained to know:

- Which equipment feeds into and out of specific equipment.
- What needs isolating for each piece of equipment to render it safe.
- When equipment is safe to be isolated.
- Specific process to occur before isolating. (eg: grinding out, draining, purging, flushing, venting, etc.)
- What sort of isolation is required for specific equipment.
- How to test isolation as safe.

Out of Service Tags

- Used to indicate that equipment is unsafe to operate.
- Anyone can place an Out of Service Tag.
- Inform your Supervisor if you do place one.
- Tag must only be removed by a competent, qualified person after the equipment is fixed.

Filling Out Your Out Of Service Tag:

- Name must be clear and understandable
- Give a clear description about the nature of the defects
- Do not enter derogative descriptions about the defects. (eg: Stuffed, Buggered.)
- When removing the out of service tag, ensure you destroy it and deposit in the appropriate waste bin.

Information Tags

- Used to pass on information.
- Should be used whenever
- barricade tape is erected
- Fill out all information
- Information tags can be
- placed or removed by anyone.

Establish and Maintain a Clean and Tidy Safe Working Area

Untidy work area

This is an example of an untidy work area. Consider all the hazards and risks that you can see..

Clean and tidy

Now look at this example of a clean and tidy working area, reduces hazards and risks to all workers, equipment and site environment..

High Risk Activities

Identify and apply site procedures for conducting high-risk activities

- Specific activities have been identified as High risk by Australian OHS Law, and as such, require special conditions or precautions to be performed.

https://www.legislation.qld.gov.au/legisltn/current/w/workhsa11.pdf

Licenses are required for high risk activities:

- Forklifts
- EWP
- Dogging
- Rigging
- Crane operations
- Bridge and gantry crane operations
- Boiler operations
- Scaffolding

- Boiler operations
- Scaffolding

High Risk Activities: Continue

Only employees trained and certified in accordance with the standard can operate, carry out or use:

- Industrial equipment as described in the “National Occupational Health and Safety Certification Standard for Users and Operators of Industrial Equipment”
- Prescribed work as defined in Schedule (A) of the National Standard 1006 – 1992 (i.e. Rigging, Dogging and Scaffolding)
- Any other plant (as defined in the Safety and Health Regulations)

Environment

Items covered in the ACT. include: | Workplace Environment and Safety
Protective Clothing and Equipment | Workplace to have adequate supply, procedures, training on use.
Use of Tools and Equipment | Workplace to have noise protection, Fumes/Dust/Gas emission controls, Electrical equipment requirements, etc.
Workplace Environment and Safety | Workplace to monitor environment and safety, (Contain/Clean up/Report spills. Report & investigate incidents/accidents/near misses), etc.
Handling of Materials | Workplace to have SDS, correct storage facilities, disposal methods, handling/lifting/carrying methods, etc.

Reflection: True/False

Reflection: Read the following statements and identify if they are True or False

Q: Danger tags can only be placed and removed by the person who has signed the tag
A: true

Q: Anyone can place and remove a personal danger tag and padlock from equipment.
A: false

Reflection: True/False

Q: Your Supervisor must be informed when you place an Out of Service Tag.
A: true

Q: Out of Service Tags must only be removed by a competent, qualified person after the equipment is fixed.
A: true

Reflection: True/False

Q: The WHS Regulations require manual handling hazards to be identified, their risks assessed, and the means by which the risks may be reduced considered.
A: true

Q: Lift and carry heavy loads correctly, by keeping the load close to the body and lifting with the thigh muscles is the correct method for carrying heavy loads if no assistance is available.
A: true

Reflection: Multiple Choice

Q: As Stated in the WHS Act, List the Systems that WHS Law States the Work Site Needs in Place for Hazard Control?
- Hazard Control (correct)
- Inching Permit
- JSA, Take 5, RTHA, Risk assessments/controls, Hazops, Hazmat, Hazchem (correct)
- Workplace to have risk management system (correct)

Maintain Personal Wellbeing

Fit for work

Fatigue

- Working whilst fatigued is as dangerous as drink driving.
- Fatigue can be work and non work related:
  - Lack of sleep
  - Too much alcohol
  - Poor diet
  - Personal issues
  - Physical demands of the job
  - Insufficient breaks
  - Hot work environment

Fit for work - Duty of Care

Duty of the Employer

Under common law and relevant occupational health and safety legislation, the company is obliged to provide safe work places and safe systems of work as well as to eliminate hazards in the workplace. Part of the duty of care includes taking reasonable precautions to ensure all individuals on its sites are in a fit state to work so as to minimize risks both to themselves and others. This Duty Of Care is to ensure appropriate adherence to, and application of the Fitness for Work Policy.

https://www.legislation.qld.gov.au/legisltn/current/w/workhsa11.pdf

Duty of Employees

Employees have a duty to take reasonable care so as not to expose themselves or others to unnecessary health or safety risks. An important part of this duty is the responsibility to ensure that they are in a fit state to work at the start of and throughout the work period. They also have a Duty Of Care to identify and report safety issues to Management.

Fit for work - Drug Testing

Drug Testing

- There is provision to make a declaration concerning any prescription and non-prescription drugs that you have recently used and also any dental treatment involving an injection which you may recently have had administered.
- Some mine sites even have policies prohibiting personnel from working on site if they take prescription drugs.
- If you are scheduled to work on these sites ensure you inform your supervisor before traveling to site, if you take prescription drugs.
- Failure to comply with the Fitness for Work Procedures for Alcohol/Drug Abuse can lead to dismissal.

Drug Testing

- Pre-employment testing, as part of a medical prior to work on most sites is mandatory
- Authorized and trained Company /Client testing officers conduct random and scheduled testing prior to or during any working day.
- Arriving at any work site with a positive drug reading can result in losing your job.
- Prescription drug taking must be identified to drug testers prior to testing.

YOUR CHOICE. MAKE IT A SAFE ONE

Fit for work - Smoking

Smoking

- Evidence has proven smoking causes health problems for smokers and other personnel exposed to cigarette fumes.
- Smoking is not permitted in any place other than in designated smoking areas
- Do not smoke in vehicles, buildings, next to flammables or in confined spaces
- Ensure you are aware of client smoking requirements when on the work site

The Effects of Smoking on the Body

Smoking and the effects on your body

Evidence has proven smoking causes health problems for smokers and other personnel exposed to cigarette fumes.  Smoking is not permitted in any place other than in designated smoking areas on a mine site or in the MAXITOOL workshop and offices.

Do not smoke in vehicles, buildings, next to flammables or in confined spaces and ensure you are aware of client smoking requirements when on the work site.

Fit for work - Alcohol Testing

Alcohol Testing

- Pre-employment testing as part of a medical prior to work on most sites is mandatory
- Employees can self test at any time using any compliant breathalyzer where available
- Authorized and trained Company /Client testing officers conduct random and scheduled testing prior to or during any working day.
- Arriving at any work site with a Blood Alcohol Content reading above 0.00 will result in a minimum of losing the days work, and in most cases losing your job.
- Be responsible, your work ethics not only reflects on yourself but it also reflects on the company you work for.

YOUR CHOICE. MAKE IT A SAFE ONE.

The misuse of alcohol and drugs

The misuse of alcohol and drugs affects peoples:

- Reaction times
- Co-ordination
- Concentration
- Ability to absorb information

Thereby increasing the potential for accidents to those affected and to other workers.

Dehydration

Dehydration occurs when your fluid loss exceeds your input from drinking.

Symptoms Of Dehydration | Re-hydrate
Thirst | Drink plenty of water
Less-frequent urination and its yellow | Get out of the sun!! Reduce body temperature
Dry skin | Plan your work in the cooler part of the day if possible
Fatigue | Wear hat brims, and cooling neckbands
Light headedness | Avoid alcohol the night before Alcohol and some drugs will increase exposure to Heat Stress
Dizziness | Apply sunscreen every 2-3 hours when work area exposed to the sun

Reflection - Single Choice

Reflection

If your Urine is Very Yellow, You are Thirsty, Working in the Sun, Fatigued and Feel a Bit Dizzy What Could You be Suffering From?

Q: If your Urine is Very Yellow, You are Thirsty, Working in the Sun, Fatigued and Feel a Bit Dizzy What Could You be Suffering From?
- Dehydration (correct)
- Exhaustion
- Diabetes
- Heat Stroke

Reflection - Single Choice

How Does Reducing Hazards in the Workplace Contribute to Safety?

Q: How Does Reducing Hazards in the Workplace Contribute to Safety?
- Reduction in Accidents & Incidents (correct)
- Keep statistics down
- Reduces work time and allows for more breaks

Identify and Report Incidents

What is a Reportable Incident?

What sort of incident needs reporting?

- Any potentially serious occurrence (e.g. Near miss)
- Any situation that could constitute a hazard to any person
- Any injury or harm to health suffered by any person in connection with work at in your workplace.
- Any incident involving damage, near miss to equipment, machinery or environment.

Why?

Incidents

Section 10 (Serious occurrence or Hazard) of the Mines Safety and Inspection Act. 1994 states:

Every person working at a mine must immediately report to their supervisor:

- Any potentially serious occurrence that arises in connection with their work.
- Any situation in the mine that they believe could be a hazard to any person.
- This includes reporting potential hazards and near misses as well as actual occurrences
- Employees are also required by law to participate in the investigations and follow up actions to minimise risk of re-occurrence

- No data no idea

- Incidents are classified into types, and also according to the level of severity
- All incidents must be reported to your supervisor as soon as practically possible
- When reporting an incident the Incident Report and Investigation Form must be used
- Work places compile incident/injury/near misses records to firstly identify numbers of each, trends and causes.
- No data no idea

Reporting Incidents

The following incidents must be reported to the relevant governing authority.

- Incidents resulting in loss of life (which must be reported immediately)
- Incidents resulting in a worker taking a number of days off work due to injury
- Incidents involving damage or potential damage to dangerous items of plant (such as boilers)

Job Safety Analysis Steps

A job safety analysis is a formal risk assessment carried out for a job before it is commenced. JSA’s are used to list the steps involved in completing a job and the hazards that are present or may be encountered whilst carrying out each step.

When you fill in a JSA you will be asked to:

- list all PPE and any controls that will be required to ensure the job is carried out safely.
- individual sign off on the JSA to prove that you have read and understood the safety measures that you must adhere to make the job safe.

Steps to complete a JSA

1. Fill out the title and administrative details at the top.
2. Break the task into simplified steps
3. Identify the hazards for each step
4. Rate the risks for the hazards in each step.
5. Put a control in place for each hazards
6. Re-rate the risks to ensure adequate
7. Take JSA to your supervisor for approval to use.

Hazard Identification

Types of Hazards

Hazards are generally separated into 6 categories. They are:

1. Physical (noise, vibration, temperature)
2. Substance (exposure to cyanide, acids, caustic soda, lead)
3. Ergonomic (work area layout, equipment design, instrument layout)
4. Radiation (ultraviolet exposure from the sun or welding, infra-red from drying or heating processes)
5. Biological (viruses, bacteria, parasites)
6. Psychological (work load, shift arrangement, workplace violence)

Identifying Hazards

There are several ways to identify hazards within the workplace including:

- Workplace inspections
- Take 5, Step back before commencing a task
- JSA’s
- SWP’s
- Instruction Manuals/Work Instructions
- SDS’s
- Notifications/Signs
- Management plans

Hazard Reports

Hazard report form must be filled out and your supervisor informed whenever a hazard can not be immediately controlled or rectified.

Reducing the number of hazards directly effects the workplace through:

- Reduction in Accidents & Incident's
- Reduction in hidden cost's
- Improvement of the working environment for everyone

Tool Storage

Storage

Store tools correctly before, during and after they have been used.

This is to minimise hazards to personnel and equipment, and so personnel know where to find them.

Hazards could include:

- Housekeeping related.
- Tools getting caught in mill rotation during inching.
- Tool becoming inoperable through mud ingress due to being left in mud.
- Tools left in a position whereby personnel can be struck by them, or other equipment can come into contact with them.

Reflection: Multiple Choice

Reflection

Identify Examples of Site Safety Compliance Documentation

Q: Identify Examples of Site Safety Compliance Documentation.
- Safety Health Environmental Management Plan outlines Company’s corporate management plan for ensuring compliance to legislative, company and client WHSE policies/procedures. (correct)
- Site lunch order form
- Job Safety Analysis are used to break tasks down into individual steps, then identify each steps hazards and put adequate controls in place to minimise their risks so the task can be performed safely. (correct)
- Safe Work Procedures provide a method for performing a specific task, which has been assessed as the safest and most efficient way of completing it. (correct)
- Medicare card
- SDS’s. Safety Data Sheets outline properties, hazards, handling methods, storage needs, disposal needs, PPE requirements, etc. for chemicals used on site. (correct)

Reflection: True/False

True/False

Q: All employees required to operate industrial equipment as described in the “National Occupational Health and Safety Certification Standard for Users and Operators of Industrial Equipment” shall have been trained and certified in accordance with the standard?
A: true

Read the following statements and identify if they are True or False

Q: When the mill is to be inched for accessing the next mill linings, a safe efficient work method is to be followed, to eliminate risk of injury, and to minimise risk of production delays.
A: true

Reflection: True/False

Q: All employees required to use any other plant (as defined in the Safety and Health Regulations) shall have been adequately trained and competent in the safe operation of the equipment
A: true

True/False

Q: Hazard report form must be filled out and your supervisor informed whenever a hazard cannot be immediately controlled or rectified
A: true