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Safety Rules
REVISION #21
ALUMINIUM METAL
PRIMARY PRODUCTION KURRI KURRI
Dear Inductee,
Good Luck!
Hydro Aluminium Kurri Kurri Pty Ltd
CONTRACTOR SITE INDUCTION DETAIL FORM
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:
ANSWER SHEET
ASSESSMENT NO: 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.
3. Bring this booklet (and completed form as per point 2) to the site
'General Induction'
O ur G o al i s ZERO
- Z ER O I nj ur ies
- ZERO Defects
C O N T E N T S
I nt ro d uct io n
Safety at the Sme l te r 1
Se ctio n No 6 S igns
Re d 35
B l ue 35
Ye llow 36
G re e n 36
Re v is ion 37
Se ctio n No 11 T he En v ir o n me nt
E n v i r o nme nt P o l i cy 68
What If Pollut ion Occurs Where I Am Working? 69
Re d uce, Re use and Re cy c le 70
Wast e D isp os al 70
Re v is ion 71
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.
Contractors - it is your
responsibility to hand
your photo identity card
into the main gate at
the end of the job.
VISITOR
What the The General Site Safety Induction does not allow
you to enter and work in areas such as -
General
Site Safety
Induction
Does not
cover
What Work This induction does not allow you to do certain work or
jobs for which you must have specific induction,
The training or authorization.
General
Site These jobs could include such things as -
Safety
Isolation procedures
Induction
Will Not
Let You Do
Excavations
Hot work
Working at heights
Points to Remember
The general induction only allows you to enter and work
unaccompanied in general areas at the Smelter.
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 No
_______________________________________________
_______________________________________________
_______________________________________________
2 Cans
3 Cigarette lighters
6 Pets, animals
7 Alcohol
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.
3 All pressurised
containers ie paint
pressure packs, aerosol
cans, etc
4 Hazardous substances
- dangerous goods
5 Cameras
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
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 No
2. What could happen if a glass bottle was put into a scrap bin
at the Smelter?
1 An explosion may occur
2 Nothing
Management demonstrates
leadership in safety.
To continuously improve
safety performance.
Point to Remember
What could go
wrong?
What am I
about to do? What can I do to
make it safer?
Duty The law and the Smelter requires everyone from you
to the Managing Director to exercise duty of care when
Of Care at work.
1 Hazard identification
OR
Team Co-ordinator
The Smelter Contract Supervisor
The Smelter Site Safety Co-ordinator
Points to Remember
You have a responsibility for safety whilst on the Smelter site.
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.
1 ________________________________________________
2 ________________________________________________
3 ________________________________________________
Housekeeping
You must play your part in keeping the site neat
and tidy with well organised work areas.
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.
Self Test
1 List the 5 items of dress/PPE you must have and wear when
necessary.
1 ________________________________________________
2 ________________________________________________
3 ________________________________________________
4 ________________________________________________
5 ________________________________________________
___________________________________________________
Yes No
They ensure that the plant and people are covered for any
emergency 24 hours of every day in the year.
The Plant The PEO exist at the Smelter site to provide the
first response to any threatening incident,
Emergency accident or major disaster.
Organisation
(PEO) The PEO crew is distinguishable by
the Red safety helmets.
1. The location.
4. Types of injuries.
What You There are two plant alarms to advise you of any
emergency.
Do If You
Hear An If the EMERGENCY is in the department you are
in, the SIREN will sound ON-OFF-ON-OFF.
Alarm
1. Look for
danger to
yourself.
2. If there is
immediate
danger,
evacuate to
the assembly
area.
However remember :-
Smelter
1. The evacuation of each section is under
the control of the Emergency Warden for
that section.
DO NOT RUN.
WALK BRISKLY
First Aid If you are injured at work, no matter how small the
injury, you are required to report it to your Team
Facilities Co-ordinator or Smelter Contract Supervisor and
report immediately to the Medical Centre so you
can receive appropriate treatment.
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?
1 ____________________________________________________________
2 ____________________________________________________________
3 ____________________________________________________________
4 What are the 3 things you must do if there is an alarm in your department or work
area?
1 ____________________________________________________________
2 ____________________________________________________________
3 ____________________________________________________________
5 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?
1 __________________________________________________________
2 __________________________________________________________
3 __________________________________________________________
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.
Points to Remember
Constantly look for hazards which may affect you.
Follow the directions displayed on all signs you see at the Smelter
Self Test
1 What do RED signs mean?
____________________________________________________________________
____________________________________________________________________
______________________________________________
______________________________________________
Vehicles You are only allowed to drive on the Smelter site for
work reasons.
On Site
Permission from the Ambulance/Security Officer is
required for access for your vehicles.
STAY AWAY
BE PATIENT
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 No
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 No
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?
________________________________________________________________________________
MUST
BE ON
SITE
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 dont follow the safety rules set
out by the Smelter or WorkCover?
__________________________________________________
__________________________________________________
__________________________________________________
No tag....No use.
disposed of correctly or
Analogue Watches
Heart Pacemakers or
other implanted
electronic devices
Types of Examples of
Barricading Practical Application
Working at heights (fall/drop zone),
Temporary Fencing excavations, restricted areas, longer term
Physical maintenance / construction activities.
Barricading Protect people and work areas from vehicle
Concrete Barriers traffic, excavations, longer term maintenance
(Most Effective) construction activities and mobile equipment.
Protect people and work areas from vehicle
Water Filled Barriers
traffic and mobile equipment.
Working at heights (fall/drop zone),
A-Frame Barricading excavations, restricted areas, longer term
maintenance activities.
Visual Barriers Working at heights (fall/drop zone),
High Visibility Cones,
excavations, restricted areas, longer term
Chains & Mesh
(Least Effective) maintenance activities.
Working at heights (fall/drop zone),
Red & White Barrier
excavations, restricted areas, longer-term
tape
maintenance activities, crane lifts, temporary
Points to Remember
All electrical tools and leads must have current inspection tags attached.
You cannot bring a hazardous substance into the Smelter without -
1. A current MSDS.
2. Correct and readable labelling.
3. A risk assessment covering the hazardous substance and the specific
task for which it is intended to be used.
4. Written approval from the Smelters Site Safety Co-ordinator.
There are strong magnetic fields in the Potline areas which may affect -
1. analogue watches
2. heart pacemakers or other implanted electrical devices
3.eftpos, bankcards, credit cards etc.
You cannot enter a confined space at the Smelter without specific training and
authorisation.
You must have an authorised work permit and written permission from the Site
Safety Team before you can bring or operate explosive powered tools on the
Smelter site.
Gas cylinders must be secured, handled safely and have a tag from the
Ambulance/Security Officer whilst on the Smelter site.
All lifting equipment to be utilised at the Smelter must have a current inspection
tag attached and comply with the relevant Australian Standards.
Entry to barricaded area is restricted to authorised personnel only.
Self Test
1 Do you need written permission to bring a hazardous substance on site?
Yes No
2 What are 3 things the magnetic fields in the Potline area may affect?
1 __________________________________________________________
2 __________________________________________________________
3 __________________________________________________________
4 What do you need to attend before you can enter a confined space at the Smelter site?
______________________________________________________________
5 All gas cylinders you bring on site must have tags from Ambulance/Security Officer -
Yes No
6 What is the requirement for the safe use of lifting equipment at the Smelter?
_______________________________________________________________
7 What are the requirements a person must have to enter a barricaded area?
1 _________________________________________________________
2____________________________________________________________
Plant Forklifts
Bridge and Gantry Cranes
Slewing and Non-Slewing Mobile Cranes
Skid Steer Loaders
Wheelbreakers
Front End Loaders
Excavators
Elevating Work Platforms (Boom type) with a reach
>11 metres
Scaffolding
To
Operate
Battery Cars
Pendant Control Cranes
Maintenance Utes and Service Vehicles
Anode Haulers
Tractors
Metal Haulers
Ore Trucks
Sweepers
Elevating Work Platforms (Boom type) boom
length <11 metres
Scissor Lifts
Regulated
Plant
If your reassessment identifies a need for refresher
training, your Team Co-ordinator will organise this for
you. Contractors are required to organise and provide
their own training and refresher training.
Authority There are some tasks at the Smelter site that we have
identified as high risk. To have the authority to work
To on these tasks you will need additional training and
Work verification. Also a work permit will be required.
Permits These high-risk tasks include (but are not limited to):
Isolation At the Smelter site there are five [5] tags that we
use.
Identification
Tags,
Out of Service Tag Caution Tag
Visitors
Personal
Lock
Identification
Tags,
Out of
Service Tags,
Alert Notices
Multilock Device
A device that allows more than one lock to be attached
to an isolator.
2. They must fit their own red personal locks and have
this witnessed.
Caution CAUTION TAGS are used to warn you that people are
testing equipment which is still energised and not
Tags under the control of a Red Lock
Points to Remember
There are many types of equipment and processes at the Smelter site
that you will require an authority to operate permit before you proceed.
Some high risk tasks have been identified at the Smelter site which
require additional training and a work permit.
The red locks are used for your personal protection and require 4 basic
rules.
1. YOU - FIT YOUR OWN LOCK
2. YOU - HAVE IT WITNESSED
3. YOU - CONTROL YOUR OWN KEY
4. YOU - REMOVE YOUR OWN LOCK
Self Test
1 What are Red Locks used for?
______________________________________________
2 What are Out of Service tags used for?
______________________________________________
3 What are Caution tags used for?
______________________________________________
4 What are Hazard Alert tags used for?
______________________________________________
5 What are the 4 basic rules for Red Locks?
1 _____________________________________________
2 _____________________________________________
3 _____________________________________________
4 _____________________________________________
Reuse
And
Reduce the amount of waste we produce.
Recycle
Reuse the material where we can.
Points to Remember
Failure to follow the rules for the Smelter environmental licence can not
only result in severe penalties, but has an impact on the quality of lifestyle
for you, your family and those in the local community.
If pollution occurs where you are working you must follow these basic
rules -
1. Take safe steps to stop it.
2. Reduce its effects.
3. Report the incident.
Self Test
1 What are the 3 basic steps to follow if pollution occurs in your
work area?
1 _________________________________________________
2 _________________________________________________
3 __________________________________________________
2 You can flush liquid waste material down sinks and drains.
Yes No
PO Box 1
Kurri Kurri NSW 2327
Australia
Statutory Declaration
Declared at ....
This .. Day of .. 20 .
Signature of JP . JP No. ..
Name of Witness .
Address of Witness .
Authority/Consent
Signature .. Date .