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SAFETY CASE FOR MAJOR HAZARD FACILITIES (RENEWAL OF MHF LICENSE (Review of…
SAFETY CASE FOR MAJOR HAZARD FACILITIES
STARTING WITH SAFETY CASE
INFORMATION ABOUT MHF
Identification of MHF and MHF operator under regulation 536
Facility address
Numbers
Street name
Suburb and postcode
Facility identification number assigned by regulator
Operator name
Operator's experience
Operator's Incident Prevention Policy
Company name notified to regulator under regulation 536
ABN (Australian Business Number)
The facility under regulation 554 and 555
Brief description of MHF under schedule 15 chemicals (schedule 18, (1) (1.1)
Nature
Operation
Main activities at MHF
Activities associated with schedule 15 chemicals
Identification by name
Quantity present or likely to be present
Physical, chemical and toxicological characteristics
Hazardous effects both immediate and delayed
Physical and chemical behavior under normal and abnormal conditions schedule 18, (1) (1.2)
Chemical and physical processes description under schedule 15 chemicals
Main units of plant used in those processes under schedule 18, (1) (1.3)
Process flow diagrams
Description of raw materials
Description of end products
Processes conditions
Drawing of MHF layout
Location of
Main storage areas
Nature
Handling
Warehouse
Bulk packaged
Loading
Transferring
Major incident hazards
Main process units
Major incident initiators under schedule 18, (1.4)
Control rooms and offices
Emergency plant and equipment
Fire water ring main
Fixed fire fighting equipment
Emergency control centre
Escape routes
Emergency assembly areas
Later proposed changes
Description of proposed changes
Alter the profile of MHF
Involve the deletion, addition or modification of any processes
Statement of how existing WHS management systems are capable of maintaining the safe operation
Scale plans of MHF
Location of MHF
Topographical information
Surrounding Land uses with zoning
Surrounding areas activities
Chemical processing
Retail sales
Sports
MHF surrounding areas where major incident may cause substantial harms
Location of identified external conditions schedule 18, (2.1)
Graphically demographic information under schedule 18. (2.2)
Local community
Surrounding land uses
INFORMATION ON RISK MANAGEMENT
Information on management of risk
Safety information
Detailed description of
Instrumentation and other equipment installed at MHF under schedule 18, 3.1(a)
Their processes and procedures (control measures)
Critical operating parameters for those critical measures under schedule 18, 3.1(b)
Process or procedure
Compliance necessary to avoid major incident
Upper or lower performance limits
Key personnel and resources under schedule 18, 3.1(c)
Internal
External
Summary of emergency plan under schedule 18, 3.1(d)
Specific information on how the plan can be expected to limit the consequences of major incident
Ensuring command structure in MHF place to communicate with workers under schedule 18, 3.1(e)
Existing control measures
Current performance
Applicable performance standard
Performance standard
Performance indicator
Effectiveness
To eliminate hazard or reducing risk
Monitoring and maintaining
Information from risk management process
Description of steps taken to ensure safety and reliability under item 6, schedule 18
Incorporated into
Design
Construction
Documentation under regulation 554
Complete list of major incidents occurring ate MHF
Summary of safety assessment conducted under regulation 555
Information on proposed changes at MHF under schedule 18, (1.5)
Altering risk profile involving deletion, addition or modification of any processes
Modification must include
Explanation of existing control measures
WHS management systems
Identifying hazard and major incidents under regulation 554
Operator should demonstrate
Recommendations given by relevant authority
Proper documentation of worker participation
Appropriate steps to identify all potential major incidents from start-up to shutdown including commissioning
Give sufficient details to assure that operator
Analyzes each incident's magnitude and severity for health and safety consequences
Understands the nature and likelihood of major incident hazard
Safety assessment under regulation 555
Operator includes all aspects of risk to health and safety
Must demonstrate
Process assessment methods suitable for major incident hazard
Should be carried out by people with knowledge and skills appropriate to plant nature and operations
Appropriate methods used to identify
All possible risk control measures
Appropriate criteria used to select or reject control measures
2 more items...
Critical controls
Proper documentation of worker participation
Level of complexity
Provide examples to show criteria are met
Examples must demonstrate
Link between identified hazards and major incidents
Should analyze how control measures in place or with agreed improvements will adequately control risks that could lead to major incidents
Range of control measures
Hierarchy of controls has been followed
Appropriate risk criteria is used
Understanding how each control measures will affect the risk levels
Clear reasons of selection or rejection of particular control measures
1 more item...
Reviewing and maintenance under regulation 534
Must review at least once in 5 years
Modification/revision
Creating a major incident that has not been previously identified
Introduction to new plant, structures, processes or chemicals
1 more item...
Changes to operation or nature of the MHF operation
Changes to worker's safety roles
Organisational change
Significantly increasing the likelihood
SAFETY MANAGEMENT SYSTEM
Reporting and investigating incidents and near misses
Defined roles and responsibilities for reporting, investigation and follow-uo
Development maintenance of skills in incident and near-miss investigation
Investigation of incidents and near misses
Disseminating lessons learnt from incidents and near misses
Follow-up of actions and recommendations resulting from investigations of incidents and near-misses
Worker consultation
Comprehensive recording and reporting of incidents and near misses
Major incident history
Major incidents occurred over previous 5 years
Include references to any recent incident which caused significant risk under regulation 559
EMERGENCY PLANS
Developing specific emergency plans and procedures based on major incident identified in safety assessment
Summary of intended emergency response strategies and objectives to mitigate incident scenarios
Emergency control systems
Evacuation procedures
Fire fighting systems
Deluge systems
Containment and drainage systems
Emergency response resources
Information provision to local community after a major incident
Training staff
Arrangements
Evacuation procedures focused on the use of emergency equipment
Refresher courses
Exercises and drills carried out to test
Emergency arrangements at all levels
MHF's interface with emergency services and local community
CONSULTATION
Emergency response equipment
Training and competency profiles for emergency response personnel
Measures to prevent damage to environment
Booms
Skimmers
Drainage systems
Neutralizing agents
Codes and standards used to determine systems
Hydrants systems
Deluge systems
Fire water systems
Maintenance of emergency response equipment and supplies
Personal protective equipment
Foam and neutralizing agents
Fire fighting equipment
Compatibility with equipment used by emergency services
Consultation with workers
Description under regulation 575
Records of attendance at risk management workshops
Dates of consultation meetings
List of workers consulted and the basis on which they are selected
Summarizing issues discussed, agreements reached and unresolved issues
Information from stakeholders
Description under regulation 572
Operators must
Must provide information to local community and local authority
Seek information from
The community
Other stakeholders
Local council
DEMONSTRATING THAT RISK HAS BEEN MINIMIZED AS FAR AS REASONABLY PRACTICABLE
Operator must include the information for those risks that have been reduced
Proves that there are clear links between identified risk controls and associated SMS, consultation and emergency plans
Identified risks are comprehensively managed by SMS elements
Shows that controls are commensurate with nature and scale of hazards
Provides evidence that risk controls are adequately reviewed prior to implementation
Demonstrates that risks have been controlled
Operator must include the information for those risks that are not reduced
Time period for implementation and controlling risk as far as reasonably practicable
MHF dealing with elevated risk levels
Information on why elevated risk is acceptable in short term
Addresses the likelihood and consequences
Implementation plan of appropriate controls
Specification
Timetables and resources
Appropriate personnel
Prioritizing risk controls
Final date of implementation
REVIEW OF THE SAFETY CASE
Under the regulation 559 or 569, it is required if
A new major incident hazard is identified
Consultation under regulation 574 and 575 needs a review
Control measure under regulation 556 or 566 does not minimize the risk as far as reasonably practicable
Health and safety representative requests the review
Modification to MHF is proposed
Regulator requires the review
Review safety assessment at least once in every 5 years under regulation 570
Operator must include the revised safety case as a part of application for license renewal under regulation 596
SIGNED STATEMENT OF CERTIFICATION UNDER REGULATION 561
Operator has detailed understanding of all aspects of risk to health and safety
Control measure must be either eliminated or minimized as far as reasonably practicable
Information is up-to-date
All persons involved in SMS implementation must have knowledge and skills
RENEWAL OF MHF LICENSE
Review and Revision under regulation 5.2
Changes can occur to
Operating procedures
Quantities of hazardous material
Introduced new hazards
Intensified existing hazards
Processes
Organisational/personnel changes
Mix of safety case personnel
Provide fresh operational experiences and insights
Help to train participants for future safety case revisions
Plant
On-site and off-site occupancy patterns
New knowledge about existing hazards which may include more severe consequences
Identifying hazards that are not previously identified
Information gathering
New facts and knowledge
Step changes in technology
New technical researches
New knowledge on chemical properties with consequences
New approaches for safety case operating experience
Modifications
Schedule 9 substances
Change in quantity
Change in phase
Introduction to a new substance or removal of an existing substance
Change of mode of transport for schedule 9 substances
Change to storage facilities
Changes to control systems
Change of location of buildings
Change of original design
Parameters for plant and equipment
Repairs to structure
Construction
New installation, plant or equipment
Introducing temporary equipment
Decommissioning of plant and installations
Performance monitoring
Audits
Control measures audits
Corporate audits for regulatory compliance
External audits
Internal SMS performance
Work Safe information
Annual inspection reports
Other communications re-performance
Notices re-controls
Review safety case methodology
Advancement in hazard identification and risk assessment methodologies
Academia
Professional bodies
Industry
Considering potential benefits
Workshops for safety assessment
Workshops for control measure review
Workshops for hazard identification
Feedback from personnel
Operators
Management
HSR
Review of hazard and major incident identification
Review of site incident/near miss data for implications for hazards and major incident scenarios
Consideration of new knowledge from external sources on potentially applicable hazards and major incidents
Quality assurance of risk register
If more than one hazard register is maintained, are the registers consistent with each other?
Are hazards correctly linked to a major incident?
Do hazards in register still exist?
Applying new methodology where necessary to analyse hazards and major incidents
Management of change documentation
Are all new plant/process equipment covered in safety case
Auditing to for analyzing identified hazards have been effective and meets procedural guidelines
Are all new identified hazards included in hazard register
Safety assessment review
Control measures
Adopted or rejected ?
Did it alter the safety assessment result?
Are they meeting the performance requirement?
New knowledge
Data changes
Changes in surrounding community
Land use
Population
Change in perception of likelihood
Applying new safety assessment methodology where it is necessary
Control measures review
Emergency plan
Review changes on personnel affecting skills, training in the emergency response plan
Changes to MHF affected the integrity of the emergency plan provisions?
Are all current major incidents identified represented in the emergency plan?
Performance review
Auditing the performance monitoring program is achieving the required frequency
Confirming corrective actions are identified and implemented when failure occurs
Reviewing whether tests used to measure the effectiveness are appropriate
Review whether the frequency of tests are appropriate
Quality assurance that altered control measure is accurately captured in risk register
Safety Management System review
Review should ensure that identified system improvement are implemented
Effectiveness of performance review
Confirm corrective actions have been identified and implemented
Review whether performance standards are appropriate
Auditing that performance monitoring program is achieving target frequency
Quality of assurance whether SMS documentation is up-to-date
Submission of revised safety case submitted 6 months prior to the expiry of current license
A copy of licensed application
A statement signed by operator's chief executive to be included in safety case
2 hard copies of revised safety case
Summary of changes made in new safety case