WMC Environment, Health & Safety Management System Worksheet Major Hazard Standard MHS-02 DocsOpen Ref: 57267, 17/10/2001 Uncontrolled copy check web for latest revision Revision Reviewed Description of Changes Date Approved 1 A Barfield Revised 17/10/2001 P Plavina 0 First Issue 12/07/2000 K Thomas WMC Resources Ltd WMC has developed this document for internal use, specific to circumstances and conditions within its operations. It is intended to provide general information and its applicability to external parties may therefore be limited. WMC makes no representations as to the applicability of the information for use by any party other than WMC and should not be relied upon as such. WMC provides no representation or warranty as to safety or business outcomes arising from application of this document and its requirements by third parties.
CONTENTS 1 Purpose 1 2 Overview of the Contract Worksheet 1 3 Completion of the Worksheet 1 1 Purpose This document is designed to assist any person responsible for scoping a Contract to define what is required of a potential contractor to enable them to comply with the Standard SAF- MHS-02. In each of these areas the following are to be checked: Does the item need to be actioned by the? What is the timing of this action? Are there any further comments/issues to be noted in relation to the item? 2 Overview of the Contract Worksheet There are 12 areas addressed by the audit document: Fire Control and Management Maintenance Requirements for Mine and Infrastructure Design Personnel and Training Flammable Materials Requirements for Underground Mobile Equipment Requirements for Fixed Mechanical Installations Requirements for Fixed Electrical Installations Requirements for Fixed Air Compressor Installations Requirements for Workshops Crib rooms, Refuge chambers and Underground Toilets Requirements for Operation and Maintenance Procedures. 3 Completion of the Worksheet This worksheet is to be completed by the person responsible for preparing the scope of the contract. The exercise is best done with the assistance of a small team who possess the skills and experience to address the issues raised. The skills should include equipment selection, purchasing and maintenance; risk assessment; design and operation; and a thorough understanding of the application of the Standard. When this exercise has been completed all identified requirements are to be referenced in the tendering information and formal contract documents. SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No 57267. Page 1 of 19
Person Completing Worksheet: Date: Person Completing Contract Documents: Brief Scope of Contract: Date: Comments: SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No 57267. Page 2 of 19
Fire Control and Management 1 1 The site shall have a Fire Control Plan (FCP) 2 1 The plan shall be developed through a process of risk assessment 3 1 The plan shall be used for day-to-day management of fire risks 4 1 The plan shall explain the fire risks present in a mine and the methods by which the risks are managed 5 1 The plan shall at the least, address the requirements outlined in the Standard SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No 57267. Page 3 of 19
Maintenance 6 2 There shall be a maintenance system that ensures the continuing safety of all underground equipment 7 The system shall establish standards of acceptable equipment condition and performance 8 2 The system shall detect and prevent the deterioration of equipment 10 2 The system shall store and manage maintenance information 11 2 The system shall report on equipment and maintenance management performance? SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No 57267. Page 4 of 19
Requirements for Mine and Infrastructure Design 12 3.1 The flammable materials and fluids stores shall be: in accordance with the appropriate standards constructed from non-flammable materials 13 3.1 The flammable materials and fluids stores shall be: separated from possible ignition sources 14 3.1 The flammable materials and fluids stores shall be: located away from collision hazards 15 3.1 Fixed fuel oil transfer systems and underground fuel depots shall be: capable of being physically isolated in the event of a fire 16 3.1 10.2 There shall be sufficient means to extinguish any fire that could occur in the mine 17 3.2 A smoke-monitoring system shall be provided where a potential fire source exists near an intake airshaft SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No 57267. Page 5 of 19
Personnel and Training 18 4 All underground personnel shall be competent for first response to fire 19 4 Only competent personnel shall handle flammable gases 20 4 Only competent persons shall use hot work equipment 21 4 The competency requirements for underground mobile equipment (UGME) operators shall include awareness of the types of fires and the methods used to control and fight fires 22 4 Fixed equipment operator training shall include the hazards related to overloading electrical systems SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No 57267. Page 6 of 19
Flammable Materials 23 5.1.1 There shall be a site policy where fire resistant materials are used in preference to flammable materials 24 All vee belts shall be fire resistant 25 5.1.1 Flammable materials shall be stored: away from heat or ignition sources clear of lighting with no smoking signs displayed 26 5.1.1 Flammable materials shall be stored in minimum quantities 27 5.1.1 Electrical switchboards shall be located away from flammable materials or tyres stores 28 5.1.1 The hot work permit system shall disallow hot work in or near stores which contain flammable materials gases or fluids 29 5.1.2 The transport vehicles for flammable liquids shall be appropriate for the task. 30 5.1.2 Only purpose-built containers that prevent spillage shall be used to transport flammable liquids underground and they shall have clear and easily understood labels 31 5.1.3 Flammable gas cylinders shall be: transported in accordance with AS 2030 transported so that no part projects over the vehicles extremity transported with the cylinder turned off 32 5.1.3 Decanting of flammable gas cylinders shall be prohibited underground SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No 57267. Page 7 of 19
33 5.1.3 Flammable gas cylinders shall be: separated from oxygen bottles by: a distance of at least 3 m, or a steel plate barrier at least the height of the flammable gas bottles next to the oxygen bottles secured so that they cannot fall over bottles of acetylene shall be stored in an upright position 34 5.1.3 Flammable gas cylinders shall be: provided with non key operated valves fitted with flashback arresters on oxy-acetylene equipment 35 5.1.3 The requirements for flammable gases shall be applied to oxygen cylinders 36 5.1.4 12.1 Proper receptacles that prevent ignition sources contacting underground rubbish shall be located in workshops etc. The site shall have housekeeping procedures 37 10.1 There shall be a sealed waste oil disposal system 38 5.1.5 Tyre stores shall not be near parking areas 39 5.2 Audits of housekeeping standards of all stored flammable materials and gases shall be conducted at least monthly and the audit results recorded 40 5.3 Flammable material, gases and fluids stores that have a significant or high fire risk (see section 1) shall have continuous thermal monitoring or smoke detection 41 5.3 Flammable material, gases and fluids stores that have a significant or high fire risk (see section 1) shall have an automatic fire suppression system or be vented to the return airway 42 5.3 Bulk fuel storage and tyre stores shall have an automatic fire suppression system, which is connected to the mine alarm system 43 5.3 The bulk fuel storage and tyre stores fire suppression system shall have the capability of manual operation at the storage inlet 44 5.3 At least 2 portable fire extinguishers shall be located close to main storage locations of flammable materials, on the intake airway side SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No 57267. Page 8 of 19
Requirements for Underground Mobile Equipment (UGME) 45 6.1 Equipment surfaces onto which flammable liquids could spray shall operate at temperatures less than 300ºC 46 6.1 Flammable liquids or gases required for mobile equipment shall have autoignition temperatures greater than 350ºC 47 6.1 Hoses shall be routed so that in the event of a burst or leaking hose, flammable liquid cannot contact a hot surface or Where routing away from hot surfaces cannot occur, all hoses shall be securely clamped and shielded so that in the event of a burst or leaking hose, flammable liquid cannot contact a hot surface 48 6.1 There shall be engine control systems designed so that if a fault occurs which could lead to an engine fire the engine stops. 49 6.1 The engine control system that stops the engine in the event of a fire shall stop the fuel 50 6.1 The engine control system that stops the engine in the event of a fire shall activate the fire suppression system 51 6.1 All electrical systems shall be designed to AS 3000 52 6.1 Electrical systems that derive power from diesel engine alternators or batteries shall be designed to AS 4242 53 6.1 An automatic means shall be provided to disconnect power from the battery to the starter motor to protect against short circuits 54 6.1 Jump-starting systems shall be purpose-designed for all electrical start equipment 55 6.1 Where cables and hoses are to pass through bulkheads, they shall have either: rubber grommets fitted, or bulkhead connections to which the cables and hoses are attached 56 6.1 All UGME, except for light vehicles, shall have: enclosed brake systems, or where open discs are installed, residual pressure monitoring and fire resistant brake hoses SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No 57267. Page 9 of 19
57 6.1 All UGME except for light vehicles shall have sealed fuelling systems 58 6.1 There shall be a system in place to: predict injection pipe failures change the pipes before the predicted failure 59 6.2 Gauges and warning lights in the operator s cab shall monitor the temperature of the automatic transmission units on LHDs and earth moving trucks 60 6.2 The cooling systems and engine shut down systems of UGME shall be monitored and include the use of warning lights for critical conditions 61 6.3 Compressors used on UGME as part of the braking system shall be fitted with temperature monitoring which provides an audible and a visual warning at high temperature 62 6.3 Compressors used on UGME for service air shall be provided with temperature monitoring that shuts the power source off at high temperature 63 6.3 An automatic fire detection and suppression system shall be installed in the engine bay of each UGME The system shall cover air compressors that supply air to the brake system 64 6.3 Two appropriately sized portable fire fighting extinguishers shall be installed on the equipment: 65 6.3 All UGME shall have at least 2 exits from any operator cab that take into account probable fire locations 66 6.3 Any remotely controlled equipment shall be fitted with remote-control activation of the fire suppression system SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No 57267. Page 10 of 19
Requirements for Fixed Mechanical Installations 67 7.1 All conveyor belts and skirting shall be fire resistant 68 7.1 Fluid couplings shall not be used on conveyors Idler bearings on conveyors shall be sealed There shall be condition monitoring on conveyor systems for misalignment, slip, over-speed, overheating and blockages, all of which trip the belt. 69 7.1 Where ventilation fans are driven by vee belts, they shall be fire resistant 70 7.1 Electrical protection against earth leakage and overload shall be provided 71 7.2 There shall be condition monitoring on all belt driven equipment for belt slip detection 72 7.2 Fixed equipment condition monitoring systems shall be tested every three months 73 7.3 Fixed equipment that has a significant or high fire risk (see section 1) shall have continuous thermal monitoring or smoke detection 74 7.3 Fixed equipment that has a significant or high fire risk (see section 1) shall have an automatic fire suppression system or be vented to the return airway 75 7.3 Areas containing fixed equipment shall have appropriate and sufficient portable fire extinguishers located on the intake airway side of the area SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No 57267. Page 11 of 19
Requirements for Fixed Electrical Installations 76 8.1 The fixed electrical installation shall be designed to minimise the need for maintenance personnel to work on live apparatus 77 8.1 Electrical equipment shall be located so that damage by impact from vehicles is minimised 78 8.1 Electrical cables shall be located so that impact from vehicles is minimised 79 8.1 Electrical transformer installations shall be designed to contain oil leaks i.e a bund large enough for the oil volume and a system in place to keep bund area clean 80 8.1 Reflectors shall be attached to fixed electrical installations and cables to make them clearly visible to operators Equipment shall have signs in accordance with AS 3000 81 8.2 Fixed electrical equipment that has a significant or high fire risk (see section 1) shall have continuous thermal monitoring or smoke detection 82 8.2 Fixed electrical equipment that has a significant or high fire risk (see section 1) shall have an automatic fire suppression system or be vented to the return airway? 83 8.2 Where fixed electrical installations are within fenced enclosures, portable fire extinguishers shall be located inside and outside of the fence, on the intake airway side of the area 84 8.3 Only non-flammable sprays shall be used during electrical maintenance 85 8.3 Electrical maintenance work shall be done only by competent, licensed personnel 86 8.3 Modifications to an electrical system shall only take place with the approval of an electrical engineer 87 8.3 Expected production-related adjustments to the electrical system (e.g. moving cables) shall only be done by a method approved by an electrical engineer/statutory appointed person SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No 57267. Page 12 of 19
Requirements for Fixed Air Compressor Installations 88 9.1 Compressors where possible shall be located on the surface 89 9.1 Compressor condition monitoring shall cover external bearing temperature, discharge air temperature, overload, oil pressure and oil level This monitoring shall trip the compressor 90 9.2 Fixed compressors that have a significant or high fire risk (see Section 1) shall have smoke detection 91 9.2 Fixed compressors that have a significant or high fire risk (see Section 1) shall have an automatic fire suppression system or be vented to the return airway 92 9.2 Where a compressor is driven by a diesel engine, the engine shall comply with the requirements of Section 5.3 SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No 57267. Page 13 of 19
Requirements for Workshops 93 10.1 There shall be minimal storage of oils, lubricants, fuel etc., in workshops 94 10.1 Chemicals that can create heat or fumes shall be stored appropriately and separated from workshops 95 10.1 There shall be separate locations, that comply with Appendix G, for welding and oxy-acetylene work 96 10.1 There shall be daily checks and leak tests of flammable gas equipment 97 10.1 Space heaters in underground workshops shall have a surface temperature less than 300 C 98 10.1 Space heaters in underground workshops shall be positioned so that rags, paper and other flammable material do not lay on the heaters 99 10.2 Smoke detectors shall be provided in offices and stores 100 10.2 There shall be at least 2 clearly marked exits from the workshop 101 10.2 Workshops that have a significant or high fire risk (see section 1) shall have continuous thermal monitoring or smoke detection 102 10.2 Workshops that have a significant or high fire risk (see section 1) shall have an automatic fire suppression system or be vented to the return airway 103 10.2 Workshops shall be ventilated into the return airway SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No 57267. Page 14 of 19
Crib Rooms 104 11.1 Crib rooms shall be ventilated 105 11.1 All internal fittings shall be made of fire-resistant materials 106 11.1 Battery charge racks shall be located in a well ventilated area separate from the crib room 107 11.1 No Smoking signs shall be displayed in the crib rooms 108 11.2 There shall be 2 exits from each crib room, or if 2 exits cannot be provided, all electrical equipment or other heat sources located away from the single exit 109 11.2 Two portable fire extinguishers shall be provided outside the crib room SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No 57267. Page 15 of 19
Requirements for Operation and Maintenance Procedures 110 12.1 The site shall have a fuelling procedure 111 12.1 The site shall have a Hot Work Permit System that covers all work conducted outside the designated hot work area 112 12.1 Workshop maintenance SWPs shall cover fire hazards 113 12.1 The following shall be included in procedures for the day-to-day operation and maintenance of mobile and fixed equipment: the removal of excess flammable materials and excess oil from the equipment before it is operated daily services shall ensure that lubricant levels in mobile equipment are adequate 114 12.1 Induction training shall include the requirement that where a machine develops a condition where heat or fuel sources may lead to a fire it shall be stopped and repaired before further operation 115 12.1 It shall be a requirement for vehicles with flat tyres not to be operated or moved, except to the nearest safe location 116 12.1 Procedures shall include a requirement that equipment shall not be left unattended within 20m of stored explosives 117 12.1 Procedures shall include a requirement that: explosives transported on or in UGME shall be in purpose designed containers and located away from heat sources detonators transported on UGME shall be in purpose designed containers that are: impact and crush resistant lockable anti-static highly visible SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No 57267. Page 16 of 19
118 12.1 Procedures shall include a requirement that for all underground main magazines: a portable fire extinguisher is located outside the magazine and a sign is located above the extinguisher stating it is for vehicle and rubbish fires only persons do not attempt to fight an explosives fire with portable extinguishers to be free of accumulated rubbish have receptacles for rubbish placed outside the magazine into which explosives are not to be disposed only charge-up or explosive transport vehicles enter the magazines 119 12.1 There shall be a fixed fire suppression system of a water spray type conforming to the relevant Australian Standards 120 12.1 Where there is no fixed fire suppression system of a water spray type conforming to the relevant Australian Standards the following shall apply: a risk assessment shall be conducted to examine the potential for a fire and its consequences and confirms no significant or high fire risk rubbish is cleared daily from the magazine to receptacles outside the magazine and the receptacles are checked for any loose explosives daily a permanent physical barrier prevents vehicle access to the explosive storage areas within the magazine, which is at least half the height of the tyre diameter of the largest vehicle to enter the magazine 121 12.2 The maintenance plan shall require full discharge tests of automatic fire suppression systems at intervals that ensure continuing effectiveness 122 12.2 The maintenance plan shall require full discharge tests of automatic fire suppression systems at intervals that ensure continuing effectiveness on remotely operated equipment, from the remote operating unit 123 12.2 Fire suppression test results shall be recorded in the maintenance system 124 12.2 An inspection and maintenance procedure shall be established to ensure the continuing effectiveness of fire hydrants, extinguishers and signs which advise of fire hazards SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No 57267. Page 17 of 19
125 12.2 The pre-start checks of all mobile equipment shall include checking: for uncontrolled ignition sources and flammable materials that the exits from the operator cab are useable the fire suppression system for rocks that could cause ignition sources e.g. between tyres and in the engine compartment 126 12.2 The 250-hour inspection on mobile equipment shall include the following: an inspection of all sources of ignition and all flammable materials an inspection of fire suppression systems 127 12.2 Supervisors shall check for explosives on or near UGME using a planned inspection checklist 128 12.2 The workshop coordinator/foreman and individuals shall monitor work, to ensure it is done in accordance with Standard Work Procedures 129 12.2 Daily inspections of fixed equipment shall include a check for ignition and flammable sources 130 12.2 The site shall have procedures for the underground transport of bulk fuel by vehicle and/or fuel transfer by pipe SAF-MHCC-02 Rev. 1 Issued: 12/07/00. Docs Open No 57267. Page 18 of 19