QENOS ALTONA SAFETY CASE COMMUNITY INFORMATION BULLETIN 2012 WHO IS QENOS? The Qenos ALTONA sites are licensed as a Major Hazard Facility (MHF) under the Victorian Occupational Health and Safety (OHS) Regulations 2007. Qenos ALTONA has three manufacturing sites that store and use Scheduled hazardous materials as defined in the regulations. These sites are Qenos OLEFINS, Qenos PLASTICS and Qenos RESINS. Employing approximately 730 people, Qenos is a cornerstone of the Australian petrochemical and plastics industry. As Australia s sole manufacturer and leading marketer of polyethylene, our products are a part of every day life and are used in a myriad of applications, including the key packaging, agriculture, automotive, water management, mining and waste management industries. We also supply a diverse range of specialty polymers. That makes Qenos a vital link in the Australian manufacturing chain. Page 1 of 9
WHAT IS A SAFETY CASE? A Safety Case is a document that details the safety management arrangements in place, including those for emergency response, to prevent major hazardous incidents and if an incident does occur, reduces the consequences. The Safety Case needs to demonstrate current and ongoing safe operation, and associated risks are reduced so far as reasonably practicable. A Safety Case is required by regulation and needs to be submitted to the regulator (Victorian WorkCover Authority - WorkSafe) for verification as part of the process for licensing the Qenos Altona site as a MHF. QENOS needs to review and revise its Safety Case on a regular basis. The maximum license period being five years before renewal is required and the Safety Case needs to be resubmitted. Qenos Altona successfully obtained its first MHF license in 2002 and the second after resubmission in 2007. WHAT IS A MAJOR HAZARDOUS INCIDENT? A major incident, if it did occur, is one that has significant consequences. The MHF regulations focus on potential incidents that have a low likelihood but also serious consequences. The MHF regulations require the risks from incidents be eliminated or reduced so far as reasonably practicable. Page 2 of 9
WHAT IS INCLUDED IN A SAFETY CASE? The Qenos Altona Safety Case comprises: A description of the Qenos manufacturing facilities, location and surrounding areas A detailed description of the Safety Management System Details of the hazardous materials present and used on the sites Details of the hazards and potential major incidents that could occur, the preventive measures and emergency plans A summary of the hazard identification and safety assessments performed Emergency response plans including information on the coordination activities involving neighbouring manufacturing sites, the emergency services and the local council. HAZARDOUS MATERIALS at QENOS Main hazardous materials present at Qenos include: LPG (Liquid Petroleum Gases): In the form of ethylene, propylene, propane, butane, butenes. These are stored as liquids that will readily vaporize or flash to form flammable gases Flammable Gases: Ethane, hydrogen and including the above Flammable Liquids: Includes but not limited to pentanes, pentenes, hexenes, gasoline type material Aluminum Alkyls: Liquid pyrophoric materials that spontaneously combust on contact with air or water Page 3 of 9
Carbon Tetrachloride: Liquid that can react with water to form acid fumes QENOS MANUFACTURING OPERATIONS The Altona sites consist of: QENOS OLEFINS: What is called an ethylene cracker, takes Ethane or LPG type feed, thermally cracks this in furnaces, the products are separated and purified. Ethylene is the main product - this is then fed as gas by pipeline to the downstream polyethylene plants. QENOS PLASTICS: Takes the ethylene and through a gas phase reaction process, produces polyethylene polymer powder. This is then treated to form an inert resin that is then transported to customers in bulk. QENOS RESINS: Takes the ethylene and via a liquid phase reaction process produces polyethylene polymer powder. This is then treated to form an inert resin that is then transported to customers in bulk. By variation of reaction conditions and additives, selective grades of polyethylene resins can be made for different markets (piping, bottles, tanks etc). Page 4 of 9
WHAT ARE THE POTENTIAL MAJOR INCIDENTS THAT MAY OCCUR AT QENOS? Safety Studies show that for all major incidents with potential offsite impacts, the likelihood of these events is extremely low or negligible. Major hazardous incidents are those that can result in serious injuries or fatalities. Flammable gas leak type releases are largely contained on the Qenos sites, although under certain rare circumstances, flammable material can cross the Qenos site boundary. If the hydrocarbon vapour is ignited this may result in a flash fire and will have radiant heat impacts. For incidents where fire impacts liquid hydrocarbon storages, this may result in sudden liquid release giving a fireball and explosion type incident. Radiant heat impacts are mainly contained on the Qenos sites although the local community may experience effects. For explosion type events that occur in Qenos process units, the radiant heat and overpressure effects are confined to the Qenos sites Other types of major incidents include hydrocarbon pool fires and jet fires. The radiant heat effects from these are contained on the Qenos sites Releases of toxic material. Dispersion modeling indicates that the hazardous incident zones are contained within the Qenos site boundaries although the local community may experience lower level effects. Page 5 of 9
PREVENTION OF MAJOR INCIDENTS Qenos uses multiple layers of protection to prevent incidents: Use of engineering standards and practices to ensure our facilities are designed, built and maintained for intended use Instrumented alarm, trip and protection systems Fire protections systems Routine maintenance and inspection and testing of vessels, piping, critical equipment and instrumentation to ensure reliability Emergency response plans (routinely tested including with the emergency services). These emergency plans also include community response recommendations in the extremely unlikely event a major incident occurs. Providing and training personnel in operating, maintenance and emergency procedures and practices Permit to work system managing the hazards and people associated with working on plant containing hazardous materials Incident reporting, investigation and follow up Audit and review of the Qenos Safety Management System that links and overlays all the systems, practices and procedures. This drives continuous improvement. HISTORY OF INCIDENTS AT QENOS There have been no serious major hazardous incidents at Qenos facilities that have impacted on the local community. Incidents have occurred where the community impacts included noise or odorous type consequences. Page 6 of 9
LOCAL COMMUNITY ACTIONS IN THE EVENT OF A MAJOR INCIDENT A Community Awareness and Emergency Response (CAER) system has been established for the Altona Chemical Complex. The Community Alarm (Siren) would be activated if an Emergency at one of the Qenos Altona Sites has a high potential to impact nearby residents. Steps to be taken are described in an Emergency Instruction Card provided to local households by the Hobsons Bay Council. The information is also provided in every edition of the Chronicle newsletter distributed by the Altona Complex Neighbourhood Consultative Group. Key actions that need to be taken if the community alarm sounds: Go inside any building - Close all external doors and turn off air conditioners Close windows and associated curtains/blinds Turn on the radio - Stereo 974 (97.4FM) or television ABC Channel 2 for Police messages Remain indoors until you are given the all clear Avoid using the telephone unless it is really urgent Cooperate fully with emergency services. Page 7 of 9
IF FURTHER INFORMATION IS REQUIRED: Qenos web site: http://www.qenos.com/internet/home.nsf/web/contactus Qenos Pty Ltd ABN 62 054 196 771 Cnr Kororoit Creek Road & Maidstone Street Altona Victoria 3018 Australia General Enquiries: Tel +61 3 9258 7333 Fax +61 3 9258 7451 Send an e-mail to enquiry@qenos.com If further information is required; Contact : Paul Kennedy (Safety Engineer): 03 9258 7297 This Safety Case summary and a copy of the associated renewed MHF license will be provided to the Altona library. A copy of the associated renewed MHF license will also be provided on the Qenos web site Page 8 of 9
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