Karratha Gas Plant Hse Handbook

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CONTROLLED DOCUMENT Title: Karratha Gas Plant HSE Handbook

Controlled Ref No: L0000RF011 Revision: 8

Name Signature Date

Prepared by: Darryl Collins

Approved by: Jeroen Buren

Custodian: Dixon Lowe

Concurrence (Agreement that must be obtained if an item is prepared external to, but impacts, a department or division. If concurrence is required, it must be noted within the body of the item).

1. Matthew Brierley

2. Alastair Bruce

3. Kelly Carter

4. Sergio Goimil

5. Robert Krueger

6. Phil Reid

Woodside Management System Sub-processes MUST obtain concurrence endorsement from BopCom. The date of the BopCom meeting where endorsement is granted should be indicated below.

BopCom Endorsement Meeting date when endorsement granted:

REVISION HISTORY

Revision Description Date Prepared by Approved by

4 Oct 04 S. Richardson J. Ryan

5 Complete re write of document Feb 07 D. Collins G. Dixon

6 Rewrite and re format May 08 D. Collins G. Dixon

7 Minor amendments to requirements (highlighted through body of text)

Dec 08 D. Collins D. Lowe

8 Amendments to document (highlighted through body of text)

Feb 2010 D. Collins D. Lowe

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Title: Karratha Gas Plant HSE Handbook




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TABLE OF CONTENT

S 1. INTRODUCTION...................................................................................................6 1.1 Health and Safety Policy ................................................................................................... 6 1.2 Environmental Policy......................................................................................................... 7 2. SITE ACCESS / EGRESS.....................................................................................8 2.1 Minimum age of entry........................................................................................................ 8 2.2 Vehicle access .................................................................................................................. 8 2.3 Prohibited items................................................................................................................. 9 2.4 Restricted items................................................................................................................. 9 2.5 Operations area access / authorisation........................................................................... 10 2.6 Removal of materials from site........................................................................................ 10 3. EMERGENCY MANAGEMENT ..........................................................................10 3.1 Emergency Alarms .......................................................................................................... 11 3.2 Mustering......................................................................................................................... 11 3.3 Vehicle Movements ......................................................................................................... 12 3.4 Injury Management.......................................................................................................... 12 3.5 Fire Protection ................................................................................................................. 13 3.6 Cyclone procedures ........................................................................................................ 14 4. HAZARD AND INCIDENT...................................................................................15 4.1 Accidents, Incidents and Hazards ................................................................................... 15 4.2 Minor Hazards ................................................................................................................. 15 4.3 Hazard Identification and Control .................................................................................... 15 4.3.1 Step Back 5x5 ................................................................................................................. 15 4.3.2 JHA.................................................................................................................................. 16 4.3.3 Level 2 Risk Assessment ................................................................................................ 17 4.3.4 HIRA................................................................................................................................ 17 5. HEALTH AND SAFETY CASE ...........................................................................18 5.1 ASSESSMENT OF MAJOR ACCIDENT EVENTS & MAJOR HEALTH HAZARDS ....... 18 6. HEALTH AND SAFETY STANDARDS...............................................................22 6.1 Golden Safety Rules (GSR) ............................................................................................ 22 6.2 PPE ................................................................................................................................. 23 6.3 Fitness for work ............................................................................................................... 26 6.4 Vehicle Standards ........................................................................................................... 27 6.5 Housekeeping ................................................................................................................. 28 6.6 Electrical Equipment........................................................................................................ 29 6.7 Tools and Equipment ...................................................................................................... 30 6.8 Flexible Hose Assemblies ............................................................................................... 31 6.9 Working at Height............................................................................................................ 32 6.10 Compressed Air Equipment ............................................................................................ 34





6.11 Gas Cylinders.................................................................................................................. 35 6.12 Signs, Barricading and Bunting ....................................................................................... 35 6.13 Powered Plant and Equipment........................................................................................ 37 6.14 Static Earthing................................................................................................................. 37 6.15 Lifting............................................................................................................................... 39 6.16 Excavations ..................................................................................................................... 42 6.17 Permit to work / ISSOW .................................................................................................. 42 6.18 Hazardous Substances ................................................................................................... 45 6.19 Welding/Cutting............................................................................................................... 47 6.20 Manual Handling ............................................................................................................. 47 6.21 Tags ................................................................................................................................ 48 6.22 Abrasive Blasting............................................................................................................. 50 6.23 High Pressure Water Washing........................................................................................ 50 6.24 Spray Painting ................................................................................................................. 51 6.25 Power Operate Winches ................................................................................................. 51 6.26 Vacuum Loading ............................................................................................................. 51 6.27 Fire Protection ................................................................................................................. 52 6.28 Pushbikes........................................................................................................................ 53 7. ENVIRONMENTAL STANDARDS......................................................................54 7.1 General Information......................................................................................................... 54 7.2 Statutory Requirements................................................................................................... 54 7.3 Woodside Environmental Standards (WES) ................................................................... 55 7.4 Site Drainage & OCW ..................................................................................................... 55 7.5 Waste Management ........................................................................................................ 56 7.5.1 General............................................................................................................................ 56 7.5.2 Responsibilities ............................................................................................................... 56 7.5.3 Solid Waste ..................................................................................................................... 57 7.5.4 Liquid Waste.................................................................................................................... 57 7.6 Oil & Chemical Spills ....................................................................................................... 57 7.7 Flora & Fauna.................................................................................................................. 58





1. INTRODUCTION Welcome to the Karratha Gas Plant, part of the massive North West Shelf Joint venture project. We hold the health, safety and welfare of each person who enters this facility in the highest regard and operate with a firm belief that “all accidents are preventable”. Whilst on this facility we expect that you will think carefully before you act and utilise your skills and knowledge to maintain and improve our health and safety standards and to protect the environment. In this handbook we have endeavoured to bring together frequently used policies, standards and guidelines into a concise single reference document, it applies to everyone working on the facility. Because the information contained within is summarised you may on occasion require further information, this is available through the Woodside intranet. The requirements contained within this handbook are mandatory requirements that apply to everyone on this site. You may not deviate from requirements within this handbook without appropriate authorisation. The requirements exist to protect not only you but also your colleagues and the facility. Where a Policy, Standard or Guideline does not exist to address a particular situation or circumstance it is expected that risk assessment tools will be thoroughly applied, and appropriately authorised, to ensure that accidents and injuries are avoided. In all that you do at the Karratha Gas Plant be constantly vigilant and alert to the hazards around you. The Karratha Gas Plant Management Team expect you to put safety first..

1.1 Health and Safety Policy Objectives We at Woodside believe that all major incidents, occupational injuries and illnesses are preventable and are fully committed to achieving our health and safety aspiration of ‘no one gets hurt, no incidents’. We also believe that attaining a world class performance in health and safety is critical to the success and sustainability of our business. Our goal is to be recognised as an industry leader in the way we deliver health and safety performance. Strategy Woodside achieves these objectives by: • Giving health and safety prevailing status over all our activities and being willing to stop or delay any work where effective risk management controls are not in place • Being constantly aware of our major accident and health risks and ensuring the right designs, plans, actions and competent people are in place to control them • Ensuring the ongoing physical integrity of our facilities and the currency and relevance of our operating procedures • Complying with all relevant laws, regulations and standards such as our Golden Safety Rules, and applying responsible standards where laws do not exist • Learning from our performance to continuously improve our processes, work practices and behaviours and sharing our lessons learned with others • Setting internal targets which drive us to continually improve our health and safety performance • Reporting our health and safety performance openly and transparently • Engaging contractors and suppliers who share our values and work with them to consistently meet our health and safety expectations • Working with our joint venturers, suppliers, competitors and regulators to raise the standards of health and safety in our industry





• Creating and sustaining a culture that empowers and rewards our workforce to act in accordance with this policy Application The Chief Executive Officer (CEO) of Woodside is accountable to the Board of Directors for ensuring this policy is implemented. This policy will be reviewed every three years. This policy applies to all personnel, contractors and joint venturers engaged in activities under Woodside’s operational control. Responsible Woodside managers will use their influence to promote this policy in non-operated ventures.

1.2 Environmental Policy Objectives Woodside believes excellence in environmental performance is essential to our business success worldwide and compatible with balancing the economic, social and environmental needs of sustainable development. We aspire to be the company of choice because of our environmental performance. We seek to reduce our environmental footprint in line with our production while delivering value to our shareholders. Setting compliance with our legal obligations as the minimum standard for our performance, we conduct all our activities with the aim of minimising adverse effects on the environment. Strategy Woodside achieves these objectives by: • Complying with all relevant laws and regulations and our standards and applying responsible standards where laws do not exist • Minimising pollution and the cumulative environmental impact of our activities at a local, regional and global level • Seeking to reduce waste and improve resource use efficiency in our design and operating practices • Supporting research to improve our understanding of the environment and thereby using sound alignment science as the basis for all our environmental decisions • Monitoring the effects of our activities and changing our practices to minimise our footprint • Setting internal targets which drive us to continually improve our environmental performance • Reporting our environmental performance openly and transparently • Learning from our performance to continuously improve our processes, work practices and behaviours and sharing our lessons learned with others • Striving to meet community expectations by listening to and addressing concerns • Being aware of and accountable for our individual contribution to environmental performance, and encouraging every employee day by day to respect our environment Application The Chief Executive Officer (CEO) of Woodside is accountable to the Board of Directors for ensuring this policy is effectively implemented through annual performance reviews. This policy will be reviewed every three years. Responsibility for the application of this policy rests with all Woodside employees, contractors and joint venturers engaged in activities under Woodside operational control. Woodside managers are also responsible for promotion of this policy in non-operated joint ventures.


2. SITE ACCESS / EGRESS Entry to site is permitted only at controlled entry points and authorised via proximity swipe card and biometric hand geometry readers. Whilst on site you must carry your proximity card at all times.

You must not use another person’s card to exit site, if you do disciplinary action and removal of site access privileges shall result. Lost or stolen proximity cards must be immediately reported at the security gatehouse.

2.1 Minimum age of entry The minimum age of entrants onto the facility is 15 years; any exceptions to this must be approved by the Vice president Karratha Gas Plant

2.2 Vehicle access Vehicle movements pose a risk to site operations through both the ignition risk they present and also their interaction with pedestrians; as a result vehicle numbers are restricted and only authorised people may drive on site. No vehicle is to enter a processing unit or drive through “road closed” barriers unless a valid permit / prior authorisation has been obtained.





2.3 Prohibited items Item Requirement Comment

Alcohol and illicit substances. Persons under the influence of these substances are not permitted on site.

Prescription medication usage should be disclosed to your supervisor.

Firearms and other offensive weapons.

Matches, cigarette lighters and similar portable ignition sources. Vehicles must have cigarette lighters removed.

Fireworks and flares.

Personal music devices including MP3 players.

2.4 Restricted items Item Requirement Comment

All mobile phones must be intrinsically safe and have a valid permit to support their presence and use on site.

Authorisation to carry a mobile phone is obtained from the Production Manager KGP

Battery operated equipment may be brought onto site into the non operations area, its use in the operations is subject to the permit to work / ISSOW system.

Smoking is only permitted in designated smoking areas

All cameras must have a valid permit to support their presence and use on site.

Permits are authorised by the Production Manager (KGP).

Explosive powered tools may only be operated by competent appropriately licensed operators.

Work permit conditions apply to the use of the equipment. All cartridges must be stored in a secure steel box when not in use; the authorised operator is responsible for their custody.





Chemicals require approval See section 6.18

Radiation Safety Officer (RSO) approval is required to bring radioactive material or equipment utilising radioactive substances onto site.

Copies of all necessary licenses are required. Appropriate storage is required.

The transportation and use of acetylene in the operations area requires Operations Superintendent approval.

Acetylene creates an explosion hazard in the nitrogen plant. Acetylene can be temporarily stored at the warehouse.

2.5 Operations area access / authorisation Any entry into a processing unit within the operational or “hot” area will require the approval of the area operator for that “unit”. Approval is usually received through contacting the relevant operator via two way radio. A two way radio must be present in each workgroup to permit ongoing communications between operations and all persons entering into processing units.

2.6 Removal of materials from site Unauthorised removal of equipment from site is theft. A valid gate pass shall be obtained prior to the removal of any Woodside materials and/or equipment from site.

3. EMERGENCY MANAGEMENT Raising an Alarm Emergency assistance can be raised by: • Phone on 90 (Central Control Room, CCR) or • By radio on channel 3 (CCR); or • By activating one of the many break glass emergency call points located throughout the facility Activating a break glass emergency call point does not automatically activate the site alarm. The alarm will sound in the CCR and operators will come to the area. If site muster is required the alarm will be sounded from the CCR. This means that if you hear a site alarm IT WILL BE GENUINE. Area Specific Alarms Include: • Fire alarms – present in buildings to warn of the presence of fire • Local area gas alarms – installed throughout process units to warn of the presence of flammable

gasses You should ensure you are familiar with the response to these alarms when working in these areas.








3.1 Emergency Alarms

Alarm Sound Action by Persons Site Emergency Alarm

1 Minute of alternating pitch

Stop all work Shutdown all equipment in operational areas Extinguish cigarettes Walk to the nearest Muster Point Vehicle drivers – pull over immediately to the side of the road, switch of the vehicle, leave keys in the vehicle. Do not park under pipe racks or obstruct emergency equipment.

All Clear 1 Minute of continuous pitch

Return to your work area Revalidate all permits prior to starting work

Alarm test 0900 Tuesday

“All Clear” is sounded first followed by “Emergency” alarm

No action is required

Building Fire alarm Bell / Claxon / enunciated message

Vacate room/office and make your way to the nearest alternative muster point. Last person out to close door behind them. (DO NOT assemble at the affected buildings muster point)

Local Gas Alarm (Operational areas) These alarms activate on detection of flammable gas concentration

Strobe light and local audible alarm

Response is limited to personnel within audible/visual range of alarm Stop all work, shutdown all equipment and ensure your work area is safe. Proceed across and upwind to a safe ground level location away from the affected area and call the area operator. Verify the location of nearest muster point in the event the situation escalates to a site emergency. If driving do not proceed through an area adjacent to a local gas alarm – Pull over immediately, switch off your vehicle and proceed as above.

3.2 Mustering All entrants to the facility must make themselves familiar with the location of the nearest muster point to their work location and an alternate. In the event of an emergency it is important that you have ready access to a point of refuge.





In a site emergency all personnel, (with the exception of security personnel and members of the emergency response team who have allocated emergency response duties), shall muster at the designated muster points and swipe their proximity card at the card reader. It is important that the reader registers a successful read, a successful read will be acknowledged by a visual and audible verification. Personnel who are unable to make their way to a muster point must ensure that they take refuge inside a suitable structure and advise Security by phone (78171) or radio (Channel 3) of their name, company, location and the names of any other persons who are taking refuge at that location. You must remain at the muster point until advised otherwise or until the all clear is sounded.

3.3 Vehicle Movements In a site emergency, all vehicles being driven must be immediately moved to the side of the roadway, switched off and the keys left in the ignition in the event that they need to be moved to permit emergency access. Vehicles shall not be parked under pipe racks or obstruct fire equipment Operational and other personnel with defined roles in an emergency may drive through the facility on cleared travel routes, these vehicles will display a rotating amber beacon affixed to the roof.

3.4 Injury Management The security gatehouse is staffed 24 hours per day and provides medical response to an emergency. All injuries sustained onsite will be assessed by site medical centre personnel prior to transport offsite There are trauma kits located at muster points. Emergency eyewash stations and showers are located throughout the facility. Persons attending the site medical centre for treatment of work related injuries/illnesses should advise their line supervision. Arrangements may need to be made to transport individuals off site or to suspend work and it is line supervision responsibility to do this. Electric shock Any person who suffers an electric shock will be required to attend the medical centre; cases will be referred to hospital for baseline ECG and doctor’s review.


3.5 Fire Protection Fire fighting equipment located throughout the facility is for emergency use only and must not be tampered with. If you require fire fighting equipment in accordance with permit conditions loan equipment can be arranged through the fire station. Ensure that any faulty equipment is promptly reported and has an out of service tag affixed. All fires and or occurrences of smouldering and/or smoke irrespective of size must be reported to the Shift Team leader in the Central Control Room (CCR).





3.6 Cyclone procedures The cyclone season runs from the 1st of November to the 30th of April annually. The KGP cyclone clean up and preparation runs concurrently with day to day activities. On the threat of a cyclone, the alert status will be displayed at the main gate and the CCR and also on the electronic board at the entrance to the facility. Cyclone alert status are: Preparation (P) - A cyclone has developed off the coast and may affect the KGP. Inspect all workplaces and park up or put away equipment not in use e.g. compressors, generators, trailer etc. Source and locate equipment required for tiedown activities. Tiedown (T) - The cyclone is likely to affect the KGP. All equipment is to be tied down or secured. Shelter (S) - The cyclone is imminent. All personnel (apart from CCR operations and Security) shall depart the facility. All Clear – All clear with caution will be issued by the Shire of Roebourne. Return to work advice is communicated to personnel via Woodside Information Line 1800 982 377 and commercial radio announcements. The Karratha Gas plant facility operates on a Prepare, Tie down and Shelter alert system rather than the community alert status.








4. HAZARD AND INCIDENT Management and Reporting All persons on site are expected to report any incident whether it results in an injury, near miss or environmental damage. Timely reporting and thorough investigation helps in providing immediate treatment of injuries, the prompt removal of hazards and is also a requirement of our license to operate.

4.1 Accidents, Incidents and Hazards All incidents must be reported as soon as possible, (in any case within the shift) to the Shift team leader, this ensures that the necessary steps are taken to effectively manage the situation. Line Supervision / Management are responsible for investigating incidents in accordance with Woodside investigation standards and procedures. The results of investigations including corrective actions are recorded in a database.

4.2 Minor Hazards Reporting hazards is just as important as reporting injuries. To make the process simple, a minor hazard report form may be used, (copies are available, from your Supervisor or the HS department). Minor hazard reporting reflects an “I see I fix” philosophy; if you encounter a hazard attempt to remove the hazard and then note the action that you have taken on the minor hazard report form. Where the hazard cannot be rectified by you or your work group then the minor hazard report will be upgraded into an incident/hazard report, this permits investigation and tracking of corrective actions. Example: A loose handrail is identified; the person finding the handrail barricades the area to prevent access and raises a work order to secure the handrail. No further action outside of minor hazard report is required. If the problem was design related however, (with the potential to affect numerous platforms) then an incident hazard report would be warranted.

4.3 Hazard Identification and Control Every task has the potential to cause harm, consideration of the hazards and ensuring that suitable controls are in place is as much a part of the job as ensuring that you have the correct spanner, multimeter or valve. Two simple processes are used on the facility for the identification and management of the hazards posed by day to day work activities - these are the Job Hazard Analysis (JHA) and step back 5x5.

4.3.1 Step Back 5x5 Step back 5x5 is a mental process to facilitate the identification of hazards at a work location. The title 5x5 is figurative and is intended to reflect an individual stepping back five paces and investing five minutes to review the environment and the task. In truth the time taken to review the hazards in the field will vary depending on the location and complexity of the task. A hazard checklist follows which may be assist in completion of process.


4.3.2 JHA Job Hazard Analysis (JHA) is a more formal means of hazard review than step back 5x5. JHA’s are best performed at the job planning stage and are a structured means of breaking the job down into its broader steps, looking at the hazards involved in that particular step and identifying controls that should be implemented to control the hazard. The results of this analysis are recorded on a form. Whilst JHA’s are best performed at the planning stage they can effectively be undertaken at any stage during the course of a job or task. Equally the JHA should be regularly reviewed during the course of the job and amended as required.








The completion of a JHA of itself does not assure your safety; you must be constantly aware of changing conditions on the facility and respond accordingly. Further detail on Job Hazard Analysis can be found in document drims # 4879818

4.3.3 Level 2 Risk Assessment Level 2 risk assessment are integral to Integrated Safe System of Work (ISSOW) process and are a facilitated team process of evaluating the work activity, potential hazards and assigning suitable and sufficient control measures to reduce the risks from the activity to as low as reasonably practicable (ALARP). A Level 2 Risk Assessment is required for unique or complex tasks or where a standard cannot be complied with.

4.3.4 HIRA Hazard Identification Risk Assessment (HIRA’s) are also integral to ISSOW process and utilise safety checklists to identify the risks associated with a task, specify the precautions and evaluate the risks involved such that, the residual risk is ALARP for the task to be accepted to proceed. This can be either a manual or computer assisted process.

http://dmslink/link/link.aspx?dmsn=4879818


5. HEALTH AND SAFETY CASE The HS Case demonstrates: • Major Accident Events (MAE) and Major Health Hazards (MHH); and their contributing hazards

at the KGP are identified and where hazards can not be eliminated, appropriate controls are implemented such that risk levels are tolerable and justifiably As Low As Reasonably Practicable (ALARP).

• Appropriate preventative and mitigative controls are in place to reduce the risks to personnel, assets and property to levels that are ALARP.

• Inherent safety & health risks associated with the operation of the facility are identified, understood, communicated and controlled as appropriate.

• Processes and systems are in place to support the adopted controls in a comprehensive and integrated manner (Health & Safety Management Process – Chapter 3).

• Workforce involvement in the hazard identification, risk assessment, and ongoing operational process in order to achieve continual improvement in performance through best practice safety management.

• Continued compliance with the KGP H&S Management Process and regulatory legislation including the DG Safety MHF Regulations.

HS Case Overview

5.1 ASSESSMENT OF MAJOR ACCIDENT EVENTS & MAJOR HEALTH HAZARDS

A Major Accident event or MAE is an event having the potential to lead to multiple fatalities. Woodside classify these events using the worst case foreseeable consequence. Due to this approach all process hydrocarbon release events are considered to have the potential to result in multiple fatalities.





A Major Health Hazard or MHH is a health hazard with significant impact on the health of facility personnel from an acute or chronic viewpoint. The following MAEs and MHHs are applicable at KGP:

A process called “Bow tie analysis” is used to analyse hazards with the potential to result in Major accidents. The process identifies the credible causes of accident events and the controls in place to guard against them. Bow Tie Diagram

Hazard




Threat

Prevention Barriers

Hazardous / Top Event

Threat

Outcome

Mitigation Barriers

Outcome


An example Bowtie is shown below, where the Cause or Threat is corrosion, and the Hazard is hydrocarbon under pressure.

Tolerable risk The risk to personnel at KGP sits within the tolerable region of the ALARP framework. ALARP is a residual risk that people are prepared to tolerate to secure benefits, provided further risk reduction is impracticable, or the cost of additional control measures is disproportionate to the risk reduction achieved. The ALARP Framework








What Measures are in Place to Minimise Levels of Risk at KGP? Prevention, mitigation and recovery measure in place include: • Plant layout & separation • Operational control system • Process design • Technical integrity • Emergency shutdown & isolation system

• Hazards & effects management for all activities

• ISSOW system • Fire and gas detection • Safe working practices & procedures • Active fire protection • Minimise ignition sources • Passive fire protection • Hazardous area classification • Emergency response planning • Golden Safety Rules Everyone can contribute to minimising risk by: • Being familiar with your HSE responsibilities • Actively participating in Toolbox meetings, Job

Hazard Analysis and Step back 5x5 • Complying with the ISSOW system • Reporting incidents and potential hazards • Taking time at the worksite to look for hazards or unsafe conditions before starting your work

• Asking your supervisor if you have any doubts or are uncertain about any aspect of your work

• Planning and taking care in your work activities

• Reading safety information provided

• Following procedures • Knowing what to do in an emergency • Keeping the worksite clean and tidy • Have Courage for Safety – speak up and stop

the job if you think its unsafe • Ask your Supervisor if you are unsure about any aspect of your work

The HSE case is available to all personnel via the virtual bookshelf.





6. HEALTH AND SAFETY STANDARDS

6.1 Golden Safety Rules (GSR) Golden Safety Rules apply to all persons employed or engaged by Woodside, they establish minimum standards applicable to work activities and are designed to prevent injuries and accidents. Workgroups must be familiar with and apply the requirements of applicable GSR’s and their associated standards to their work activities. The following GSR references are provided GSR Associated standard Foundational GSR Permit to Work Permit to Work Standard

Confined Space Entry Confined Space Entry Standard

Electrical Isolation Electrical Safety Management Standard

Working at Heights Working at Height Standard

Ground Disturbance Ground Disturbance Standard

Lifting Operations Lifting Operatrions Standard

Driving Safety Driving Standard

Management of Change Management of Change

Mechanical Isolation Process / Mechanical Isolation Standard

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6.2 PPE Minimum standards exist for personal protective equipment on site and these must be complied with. PPE is the last line of defence between the wearer and a hazard, it shall be appropriate to the task/s being completed and as established by risk assessment. It is the responsibility of the owner to maintain PPE in good, fit for purpose condition.

Area Minimum PPE Requirements Non Operations • Clothing appropriate to office environment; and

• Enclosed footwear Additional PPE will be required dependent on work activities

Operations • High visibility fire retardant shirt and fire retardant pants; or

• High visibility fire retardant coveralls • Safety footwear; • Safety glasses; • Gloves; and • Hard hat Additional PPE will be required dependent on work activities

Warehouse (outside of office areas)

• Long sleeve high visibility shirt; • Long pants; • Safety footwear; • Gloves; and • Safety glasses Additional PPE will be required dependent on work activities

Workshop • High visibility fire retardant shirt and fire retardant pants; or

• High visibility fire retardant coveralls • Safety footwear; • Safety glasses; and • Gloves (outside of designated areas such as crib rooms and walkways) Additional PPE will be required dependent on work activities

Persons New to Site Persons who have not been to the KGP before or who have not visited in the last year will not be familiar with the plant layout or the emergency response procedures. To make you more visible, particularly during an emergency and in order that an experienced plant person can assist you, you are required to wear a green safety helmet. The green helmet must be worn for the duration of your visit or for a period of four weeks.





Applicable standards for PPE Safety Helmets Must be used in compliance with AS/NZS 1800 and when working at height be fitted with a chin strap. Helmets must be replaced after 24 months for outside workers otherwise 36 months. Bump caps may be used during certain activities subject to risk assessment. Bicycle helmets Bicycle helmets must be compliant to AS/NZS 2063 Safety Glasses/Eye protection Safety glasses must be medium impact rated in compliance to AS/NZS 1337. Only close fitting approved eye protection may be worn. The following guidelines apply to eye protection selection:

Eye Protective equipment Suitable for

Safety glasses (medium impact rated, clear or tinted including prescription glasses)

Drilling / hammering Chipping Fitting or removing steel strapping or banding Outdoor or indoor maintenance / construction work Hand/brush painting

Dust protection goggles (e.g. Bolle Tracker complete with head band)

Cladding / lagging removal Scale removal, wire brushing Scaffold disassembly Enclosure / habitat dismantling Dusty environments (e.g. excavation, removing overhead ceiling tiles, etc)

Mono goggles Chemical handling per MSDS/Health Risk Assessment Entry into demin/acid plant

Safety glass & face shield or goggles & face shield combination

Using Hytorc equipment, Plarret and Rattle Guns Grinding Scabbling

Air fed helmet Blasting and spray painting activities

Footwear Enclosed footwear covering the entire foot is the minimum standard for entrance to the facility. Safety Footwear Must be compliant to AS2210 with a nitrile outer sole and type 1 rated with class 1 toe cap Rubber boots shall meet similar specifications and include a steel toe cap.





Hand Protection Hand injuries are among the most common type of injury that occurs on site, most of which could be prevented by wearing the appropriate type of glove. As specified in minimum PPE requirements table and when conducting manual work anywhere on site, gloves must be worn unless risk assessment shows that to do so create an increased level of risk, (for details on risk assessment see section 4.3. The following guidelines apply to glove selection:

Glove type Suitable for

Rigger / heavy duty gloves All purpose general glove used for protection against chemical residue, abrasion and or heat/cold hazards

High flex / general duty gloves

All purpose general glove used for protection against chemical residue, abrasion and or heat/cold hazards. Provide increased dexterity where completing finer tasks

PVC General purpose

Chemical resistant glove for use where contact with oil, grease, diluted acids and solvents is expected. PVC will not provide a barrier against hydrocarbon solvents (e.g. toluene, hexane, etc)

Nitrile Chemical glove/gauntlet

Chemical resistant glove for use where contact with oil, grease, acids and solvents is expected. Will not provide adequate protection against strong oxidizers

Latex disposable gloves

Used for protection against incidental contact with chemicals including: laboratory chemicals Cleaning agents Biological materials and human waste from medical treatments

Respiratory Equipment Equipment shall be selected and used in accordance with AS/NZS 1715, (this includes the wearer being clean shaven) and as a minimum meet the requirements for respiratory protection specified in the Material Safety Data Sheet (MSDS). Personnel using respiratory protective equipment shall be trained in the selection, use, fitting and maintenance of the equipment. Self Contained Breathing Apparatus Self Contained Breathing Apparatus (SCBA) may only be used in circumstances where there is no alternative method of performing that task safely. All persons required to wear SCBA must be deemed competent and have attended a Nationally Accredited SCBA Wearers Course. Hearing Protection Hearing protection must be worn when in an area marked with signs ‘Hearing Protection Required’, in (operating) process areas and when performing any task that produces excessive noise. As a guide, if you have to raise your voice to be heard, wear hearing protection. In some instances





double hearing protection (plugs covered by muffs) may be required, see your Supervisor for clarification. Special Personal Protective Equipment Hair nets and beard nets must be worn when working with or near rotating equipment and in kitchen environments. Harnesses / Fall protective devices Harnesses and fall protective equipment shall comply and be managed in accordance with Australian Standard 1891 and Working at heights procedure (L0000AG150174). Fall protective equipment (excluding fixed equipment) shall be inspected at 3 monthly intervals; equipment shall be tagged to the same conventions as lifting gear. Personal flotation devices, (life Jackets) Personal flotation devices must be worn when accessing dolphin berths and for all work over or on water. Personal flotation devices (PFD’s) shall have an inflation buoyancy of no less than 275 newtons and be fitted with a whistle and reflective tape. PFD’s are inspected on an annual basis with a prominent tag affixed to indicate currency of inspection; it is the user’s responsibility to complete a visual inspection each time this equipment is worn.

6.3 Fitness for work Fit for work means that an individual is in a state (physically and psychologically) to perform tasks assigned to them competently and in a manner which does not compromise the safety or health of themselves or others. An individual’s Fitness for Work may be compromised due to a variety of factors including the adverse effects of medical conditions, level of physical fitness, fatigue, heat and psychological stress or the use of alcohol and other drugs (AOD). All personnel entering the KGP have a duty of care for ensuring that they are fit for work. This duty of care also involves:

• Notification of any medical condition, (past or present) that may affect your fitness for work or affect medical treatment

• Report to work in a fit condition • Comply with the KGP AOD Policy and Testing Procedure • The appropriate use of medication • Self management – looking after yourself • Peer management – looking after your colleagues • Report hazards and/or unsafe acts, including someone that may be unfit for work as a

result of AOD. Work Rosters Due to the 24 hour nature of operations activities often require work outside of normal business hours; fatigue management guidelines exist to manage these risks. It is a requirement at the Karratha Gas Plant that work activities be planned to take account of the effects of fatigue and their ability to increase the risk of accidents and ill health. The following general requirements apply to fatigue management:

• No person shall remain onsite for greater than 13.5 hours in any 24 hour period • No person shall return to work between shifts within a 10 hour period • No person shall work greater than 78 hours per 7 days outside of approved rosters





Rosters shall be arranged in accordance with the KGP Fatigue Management guidelines. Any deviation from established fatigue management guidelines will require approval. Further detail on Fatigue Management KGP can be found in document #L0000MF5490739 Noise Whilst efforts are made to reduce noise levels on site, equipment and/or work activity noise levels can exceed the exposure standard set out in the National Standard for Occupational Noise [NOHSC: 1007(2000)] (or equivalent local legislation) which is:

• An average daily noise level (LAeq, 8h) of 85 dB(A) and • A peak noise level of 140 dB(C)

Workgroups must wear properly fitted hearing protection where noise levels exceed exposure standards. Areas likely to exceed exposure standards include operating trains and units, workshops, blasting and painting operations, etc. Audiometric testing is available to employees likely to be exposed above the exposure standard. The testing commences on initial appointment (baseline), every 12 months and then on exit from Woodside. If you have some concerns with noise in your work area, contact your Supervisor or H&S Adviser.

6.4 Vehicle Standards Vehicle activities pose some of the greatest risks to the operation due to the capacity for collision and the ignition risk that they create. Vehicle access to the facility is closely monitored with access restricted to vehicles required for business purposes. Vehicle access controls are detailed in part 2.1 Vehicles shall be registered and operated in accordance with West Australian road traffic regulations and sign posted requirements. Vehicles may only be driven on gazetted roadways and parked in designated parking areas. Entering processing units (crossing the yellow line marked on roadways) requires a valid permit and area operator approval. Grid mesh throughout the plant is not traffic rated, intended crossing points shall be established with the area operator. Drivers shall hold a current license for the class of vehicle they are operating. Are authorised to drive on site and are responsible to ensure that the requirements of Woodside standard – Driving are met, this extends to the standard of the vehicle, load security and fatigue management. In the Operations area keys must be left in the ignition at all times in the event that the vehicle needs to be moved in an emergency. Vehicle Movements in an Emergency In a site emergency, all vehicles shall be parked off the roadway in a safe location, switched off and the keys left in the ignition.

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Heavy vehicles (>4500kg GVM, Earthmoving and load shifting equipment). Oversize vehicles and/or vehicles with restricted vision must be escorted when travelling on roadways and when manoeuvring in and around plant and structures. Consideration should be given to the nature of operations and adequate segregation established between the heavy equipment and its operational area and pedestrians. Heavy vehicles shall be fit for purpose and fitted with the following equipment as a minimum: • Audible reversing alarm which can be clearly heard by pedestrians in proximity to the vehicle • Where a risk assessment demonstrates that there is an unacceptable risk of roll-over due to

terrain, vehicle type or work conditions then a properly engineered roll-over protection device shall be installed

• A minimum 4.5kg dry chemical powder fire extinguisher When unattended blades, buckets, tines, etc of mobile plant shall be lowered to the ground. Forklift Operations Every year in industry people are killed in forklift accidents. To minimise the risks associated with forklift use on site the following rules apply: • Seat belts must be worn • No one may operate a forklift they are not familiar with or in which they have not received training • The forklift operator is responsible for performing daily pre-start inspections and completing the

pre-start checklist • Forklifts are not to be used to carry loads over long distances. Use alternatives transport such as

trucks or utilities • Capacity charts and operating manuals must be readily available to forklift operators Personnel must only be lifted using an approved personnel cage with the authority of the Area Supervisor. Further detail on Vehicle standards can be found in document #W1000AF2662505

6.5 Housekeeping An untidy work area is hazardous and leads to incidents, injuries and inefficiency. Use the appropriate bins/skips provided and remember that “there is a place for everything and everything belongs in its place”. Due to the proximity of the facility to the ocean there is a risk that anything falling to grade will cause ground contaminations and/or migrate to the ocean. It is a requirement that waste/spills are managed to minimise this risk and instances of rubbish or debris in plant drains reported immediately to your Supervisor. Work areas should be managed to reduce the accumulation of surplus materials with lay down areas established that do not interfere with critical equipment, (plant controls, fire fighting equipment, etc) and access/egress ways. Work areas should be cleaned regularly with waste disposed of in accordance with the site waste disposal guidelines contained in section 7.5 of this book.

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The following specific requirements apply: • Spills of petroleum products, chemicals or other materials must be reported immediately

according to site procedures and immediate spill containment and clean up actions taken (safe methods to be used)

• All activities involving the use of temporary tankage, storage, loading/unloading of chemicals, fuels and similar bulk materials (except refuelling of equipment from fuel tankers) must be carried out with spill containment and control in mind. Consideration must be given to the installation of temporary bunded areas during project planning and/or when conducting JHA’s for the above activities

• Cleaning, washing, abrasive blasting and hydroblasting of process equipment which has been exposed to chemicals, oils, acids, bases or other contaminants must be performed in run off contained areas

• No open burning of materials, brush, tires, construction materials, oils, etc. is allowed • Chemicals shall be approved for use in accordance with the Woodside chemical approval

process (sec 6.18)

6.6 Electrical Equipment A large variety of portable electrical equipment is used on site and when it is not used or maintained in the correct manner the results are potentially lethal. The following requirements are designed to minimise this risk and are mandatory on site: • All single phase generators used on site, including mobile welders, must comply with AS 2790-

1989 • Any electrical equipment fitted with a flexible lead and plug top must be inspected, tested and

tagged, (temporary equipment brought on site by visitors for use in buildings/training facilities is exempted from testing for the duration of their visit but it must be in good serviceable condition).

Where the equipment lead is flexed during use, the frequency for inspection, testing and tagging shall be 6/12 monthly, i.e. portable drills etc. Class 1 equipment shall be tested every six months. Class 2 equipment is double insulated and shall be tested every 12 months. Where the equipment lead is not flexed during normal operation the test and tag frequency shall be five years, i.e. computer power, fridges. Damaged electrical equipment (insulation, faulty switch, etc) shall be tagged “Out of Service” and sent for repair. Include a description of why the unit is faulty. • Extension leads shall not exceed 32 metres in length and shall use heavy duty flexible cable,

(min 1.5mm2) • Extension leads shall be elevated a minimum of 2.4 metres at the lowest point and secured to

stable supports not more than three metres apart. Power leads shall where supported from metal rails and scaffolding be carried by insulated hooks

• Extension leads shall not be routed along access ways or walkways and where potential for mechanical damage exists, the lead/s shall be provided with additional protection

• All extension leads shall be isolated when not in use and removed from the work area as soon as the task has been completed

• Portable ELCB boxes shall be used to distribute power and not as an in line adaptor to permit the infinite extension of a power supply i.e. an ELCB box may not be plugged into an extension and





have an extension lead running from it so that the total length of power supply exceeds 32 metres.

• Only power boards with overload protection and individual switches (material No. 10031201) are to be used in office locations. Double adaptors must not be used on site

• No person other than a WA licensed electrician shall make any repairs or an alteration to power tools, plugs, fittings, leads or other electrical appliance or any fixed wiring installation

• Electrical distribution boards/boxes shall have clear identification, doors properly secured and unobstructed access

• When connecting or disconnecting tools from the electricity supply, make sure that the switch from the electricity supply is “OFF”

Further detail on Electrical standards can be found in document #W1000AF3194712

6.7 Tools and Equipment The risk of injury associated with using tools and equipment varies depending on the type of tool, the person using it and the surroundings in which it is being used. It is the users responsibility to assess the risks of injury before using any tool, with particular focus on ensuring the tool is in good condition, is fit for purpose, the best suited for the job and the user has the competency necessary to use the tool. The following requirements are designed to minimise the risks associated with using tools and equipment and should be referred to before commencing work with any tool: • Minimum PPE levels as specified in section 6.2 shall be worn • Use the correct tool and then, only in the manner for which they were designed. Do not misuse

tools, for instance, by using scaffold tubes on ratchet spanners, using a hammer on screwdrivers, using tools as hammers etc. Pre-job risk assessment should be used to determine if work methods are appropriate

• All tools shall be maintained in a safe working condition • All tools shall be inspected before use. Do not use damaged or worn tools • Damaged tools shall be tagged “Out of Service” and returned to store. Include a description of

why the tool is out of service • To help keep tools in good condition make sure they are properly stored when not in use • Ensure cutting tools are kept sharp • Guards are fitted to some tools and equipment to prevent injury. NEVER use a power tool if

guards are not in place • Current colour coded tags shall be fitted to all electrical tools and equipment • A “deadman” switch that prevents the tool from being locked in the ‘on’ position should be in

place • When working at heights, tools and equipment are to be properly secured to prevent them falling

to lower levels, this includes equipment such as magnetic based drills which can fall if power supply fails

Hytorc Equipment Hytorc equipment shall be used in preference to flogging spanners. Only compatible hytorc systems shall be used on site, equipment shall not be modified to permit interconnection of equipment. Sockets must be compatible with generated forces and fitted with protective sheaths to contain socket fragments should the socket fail. Only recommended reaction arms should be used. Grinders






Maintenance Superintendent approval is required before any person uses a 9” grinder. Battery Operated Equipment Non intrinsically safe battery operated equipment and batteries are potential ignition sources. Precautions shall be taken to ensure that there is no inadvertent energisation of this equipment whilst it is transported through the operations area. Trigger operated equipment is of particular concern and steps should be taken including separating the battery from the equipment.

6.8 Flexible Hose Assemblies

Hoses, fittings and the method of attachment comprise flexible hose assemblies. Fail Safe: Hose and hose assemblies can and do fail without warning for many reasons. Equipment must be designed and operated in a fail-safe mode, (considering also segregation distances), so that failure of the hose or hose assembly will not endanger persons or property. Flexible hoses shall:

• Be in good condition • Have standard fittings • Be suitable to the service • Be maintained • Be tagged in accordance with standard, (typically unique identification number)

Prior to use, all hose assemblies must be inspected by the person or persons using the equipment, any defects warrant the hose out of service. Inspection should look for signs such as:

• Hose cover damage, cuts, abrasion or exposed reinforcing material • Stiffness or hardening can lead to failure and caused by sunlight, ozone or chemical attack • Changes in colour, may indicate chemical attack, ozone or ageing • Blisters in cover, chemical attack, permeation in early stages of leakage • Kinked or flattened hose, restricted flow, internal hose damage • Leaking • Damaged reinforcing material

All portable hose assemblies brought on site must comply with site requirements, hoses shall not be modified nor shall adapters be fabricated to accommodate incompatible hoses. Any deviation from site standard shall be subject to engineering approval. Consideration for static electricity build up must be made (see section 6.14)

AIR ¾” Nitto Hi cupla quick connect, ½” Atlas Copco quick connect

WATER Minsup claw fittings

NITROGEN ¾” camlock

OIL “IT” ¾” or 1” self sealing quick connect fittings

All portable pneumatic type hoses (compressed air, nitrogen) used on site must be fitted with whip checks.





Further detail on flexible hose standards can be found in document #A3000SM146602

6.9 Working at Height All efforts shall be made to minimise fall/drop risks during activities at height. Where a potential exists for a person or equipment to fall ANY distance from one level to another, effective controls shall be implemented. Effective measures include but are not limited to:

• The provision of edge protection (guardrails) • The use of a scaffold or elevated working platform (boomlift, cherry picker, scissor lift) • The use of drop sheets and tool lanyards • Tool belts • The use of fall protection systems • Catch platforms • Exclusion zones below the activity

Activities shall be planned taking into account skills required, equipment available, impact of climatic conditions, loadings created or potentially created by equipment, clearances and rescue requirements. Two items frequently overlooked in the planning phase are dropped objects and personnel rescue. Careful consideration is required of the potential for objects to drop from one level to another, something which can occur during the course of operations and / or maintenance, (an operator looses grip of a wheel key or a bolt or screw driver drops through grid mesh). Items have and do fall from tool bags, out of pockets when climbing steps, from top pockets when someone leans over. All credible sources of equipment falling from height should be considered and steps taken to reduce the potential of this. Due to the uncontrolled nature of the practice throwing items from one level to another is prohibited on site. It is a requirement of workgroups using fall protection equipment that they have capability within their team to retrieve a member from a fall situation back onto a safe landing. Elevated work Platforms Persons who operate an elevated work platform must hold an appropriate national certificate or licence and be competent in the use of the particular model which they are operating. The equipment shall be used in accordance with the manufacturer’s guidelines and instructions in all cases. Elevated work platforms are designed to be used as a safe landing for the completion of work at height they may be used to transport hand tools and hardware to the work location but are not intended to be used as a material hoist. In certain cases the use of an EWP may be deemed the most appropriate means of transporting materials to height, (i.e. carriage of scaffold equipment, carrying of air filters) a documented risk assessment, approved safe work instruction or similar shall support this activity. Persons working from a boom type elevating work platform must use fall protection equipment rated for fall arrest service secured to an anchor point inside the basket.






Personnel shall be competent in the inspection, fitment, installation and use of fall protection equipment and devices. Holes, Penetrations and Open Edges Any hole or penetration through a floor or walkway or open edge must be protected with either fixed guard rails or secured covers that have a load rating suitable for the likely service. Signage shall be posted either on the guard rail or fixed to the cover to alert of the danger. All gridmesh panels shall be securely fixed immediately they are replaced into position. Scaffolding Scaffolding shall be designed and installed so that where possible access/egress points are maintained, plant controls and valve access is not obscure or impeded and emergency equipment operation is not compromised, (line of sight fire detectors, fire fighting equipment, fixed deluge system – “shadows” created). Scaffold shall not be supported by process equipment (e.g. piping, vessels, valves etc). All scaffolding shall be erected/altered/dismantled under the charge of a competent certified person. Access ladders to platforms shall not exceed 4 metres in length and spring loaded gates or drop bars shall be provided to protect each access onto a platform. Modular style scaffold, (eg. aluminium portable style) may be erected up to a height of four metres by an uncertified person, (note: Four metres represents a total fall height, i.e. modular scaffold erected on the edge of a 10 metre landing would need to be erected by a certified person). All entrances to the scaffold must carry a “Scafftag”. It is a requirement that scaffolds are inspected at least every 30 days by a competent person. Scaffolds not fit for service must be barricaded, signposted and the scafftag removed. Scaffolding used to suspend loads or lifting apparatus of a combined weight ≤500kg shall be approved by an individual holding an advanced scaffolding certificate. For services greater than this engineering approval shall be provided. Ladders Ladders are used for the purpose of access and egress. The use of ladders as working platforms except for simple tasks such as inspection, changing of light globes or similar is not permitted. Other short duration activities proposed to be completed from ladders must be supported by a risk assessment with consideration given to the use of platform style ladders. Welding, cutting, grinding or similar activities are not permitted from a ladder. The following guidelines apply: • Choosing the type of ladder appropriate to the task. All portable ladders must comply with the

appropriate Australian Standard • Ladders shall not be overloaded including carrying of more than one person • Provide a slip resistant base, rungs or steps • Maintain a 1:4 ratio feet placement distance from a support structure to the working height of the

ladder • When a person is stepping from the ladder ensuring that they have a firm and level work

platform, free from obstructions to step onto





• Ensuring that the stiles of the ladder extend at least 1m above the stepping-off point and that the ladder is securely fixed. Sufficient platform area must be provided at the stepping off point

• Ensuring the ladder is the right height for the task to avoid reaching or stretching. Keep the body centred between side rails at all times

• Secure the ladder against displacement or having another person hold the base of the ladder • Make sure all locking devices on the ladder are secure • Use the ladder on firm, stable and level ground • Wear a fall protection system if there is fall risk • Ensure that metal or wire bound ladders are never used close to energised power lines • Ensure the ladder is in good condition • Maintain three points of contact when climbing ladders, (tool pouches, bags and haul lines

should be used to lift equipment) • Use the ladder in accordance with manufacturer’s guidelines, do not work above or from rungs

that carry warning decals against this • Step and trestle ladders should be used only in the fully open position. A step ladder may be

used in the closed position by leaning against a support; however care must be taken to ensure that the load is carried by the front stiles only

Rope Access Any activity that requires an individual to be positioned or suspended by rope/s to complete the work should be regarded as rope access. Rope access is a specialist activity and shall only be completed or supervised by IRATA accredited personnel. Further detail on Working at height standards can be found in documents #W1000AF2656804 and L0000AG150174

6.10 Compressed Air Equipment Compressed air poses a risk due to its capacity to create air embolisms under the skin and the generation of static electricity. The following applies to the use of compressed air: • Prior to using any compressed air tool the user must conduct visual inspection of hose, tools and

any couplings looking for damage, wear or leakage • Compressed air must not be used as a means of personal cleaning or for cleaning down

workbenches. Never discharge compressed air against any part of your body, clothing or at any other person

• Hoses shall be managed and used in accordance with section 6.8 Flexible Hose Assemblies • Air hoses are to be routed in such a way as to prevent damage by vehicles or equipment • The air supply is to be properly isolated and depressurised before connecting or disconnecting

any tools or other hoses • Hoses must not be left connected to a compressed air source that may be inadvertently turned

on causing whipping of the hose and potential serious injury • Hoses used in elevated areas are to be secured • All portable air manifolds shall have ball valves fitted to all outlets • Flexible air hoses for use with hand tools should be equipped at the free end with self closing

valves to shut airflow should the tool be removed (quick connect couplings) Where compressed air must be used for the cleaning of small parts or equipment that cannot be cleaned effectively by other methods:


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» Air pressure must be kept as low as possible » Mono goggles or full face shields with safety glasses and appropriate hearing protection must be worn » Measures must be taken to provide protection to passers-by and may include the use of screens or special enclosures

6.11 Gas Cylinders There is significant stored energy in gas cylinders and the storage, handling and use of them must be in consideration of this. Cylinders must only be stored in dedicated storage areas with good natural ventilation. A minimum distance of 3 metres shall be maintained between incompatibles including different class chemicals/gases, ignition sources and amenities (offices, workshops, ablutions, etc). Cylinder fittings must be kept clear of oil, grease and other contaminants. Cylinders in transport must be kept upright and secured against movement, (approved bottle racks are the preferred means of achieving this); flammable gas cylinders must be transported separate to drivers cab with all gauges and regulators disconnected. When not in use cylinders shall be isolated at the valve, empty cylinders must be removed from the work area. All cylinders must have contents tag (Full, In Use, Empty) in place.

6.12 Signs, Barricading and Bunting Standard signage conventions as outlined in AS 1319 are applicable on the facility. Signs are provided to control safety related behaviour, warn of hazards and provide emergency information, you are required to obey the conditions specified on signs.


Signs shall at all times be clearly visible, clean and legible. Barricading Barricading shall be placed around all areas where personnel may be exposed to danger, this includes but is not limited to: • Being struck by materials • Falling into open excavations or penetrations • Hazards, toxic or flammable substances • Specific work processes (i.e. radiation, pneumatic / hydro testing, scaffolding, rigging, spray

painting, abrasive blasting, crane operation, etc) General Requirements for Barricading/Bunting Rigid guard rails shall be used to protect persons from open edges and penetrations/holes in grid mesh/floors. Risk assessment may identify other areas where hard barricading is required which may include high traffic areas, (vehicular/pedestrian). Barricading shall not be attached to process lines and must be maintained at a height of around 1 metre above the ground. Barricades shall carry an information tag with the following detail recorded:

• The name of the person in charge of the work area • The date of erection • Their radio channel • The purpose of erection








Barricading shall be maintained daily such that it clearly delineates the area of exposure and be removed immediately after use. Additional Requirements (Roadways) Barricading erected on roadways shall make provision for traffic flows and be visible at night. Appropriate notifications of traffic restrictions shall occur. Further detail on barricading and bunting standards can be found in document #L0000AF131419

6.13 Powered Plant and Equipment Powered plant encompasses generators, compressors, high pressure water pumps, lighting towers, etc. This equipment must be in good condition and compliant with Woodside standards to be brought onto site and must be maintained to the same standard. In particular the following apply: • All warning lamps and gauges must be operational and the equipment fitted with a clearly

identified emergency stop button. • Operating manuals/instructions must be provided and be readily available to users of engine

driven equipment. • All relevant safety and health warning signs and notices shall be affixed. • Evidence of registration and log books shall be maintained with the equipment. • ELCB and Electrical protection relays shall be tested with proof of currency recorded by way of

tagging. Powered plant and equipment is considered an ignition source. Operator approval/permission must be given before equipment may cross or be operated inside a yellow painted line, (crossing a yellow road demarcation line is considered entry into a unit). Due to the risk of ground contamination from oil leaks and spills during refuelling, stationary engine driven equipment shall where possible have drip trays placed underneath the equipment and/or bunding arrangements in place. Generally there is no requirement to bond the frame of portable generating equipment to earth, this includes lighting towers. Trailers must have a suitable jockey wheel arrangement to remove the manual handling risk associated with its connection and disconnection. Equipment must be shutdown during refuelling operations and spill clean up and fire extinguishment equipment available. No “siphoning” is permitted on site.

6.14 Static Earthing The purpose of this note is to present simple guidelines and a standard of electrical requirements to prevent the build up of static electricity. The guidance is intended for routine temporary operations, including blast cleaning, fuel trucks, high pressure jet washing, and vacuum equipment. Operational activities such as flushing and draining shall have receptacles earthed


For non routine operations, where there is a higher risk of explosive atmosphere being present during the operation, the precautions must be discussed with the Senior Electrical Engineer or designate. As a minimum requirement, the following precautions should be taken when using equipment as described which may generate static electricity. In a Non Hazardous Area (e.g. Workshop) The compressor/vacuum equipment including the nozzle, shall be electrically bonded to the work piece using flexible 10mm2 minimum sized cable (AS/NZ2381.1) or alternatively use electrically tested antistatic hoses. Electrical connections to the equipment must be made with either a bolted crimped lug connection or a substantial clamp arrangement. In a Hazardous Area The compressor/vacuum equipment including the nozzle shall be electrically bonded to the work piece and plant earth using flexible 10mm2 minimum size cable (AS/NZ2381.1). Good contact must be achieved between the bonding surfaces, (nozzles, flanges, compressors, work piece and plant earth). Where possible tested anti static hoses should be used as this will reduce the amount of electrical bonding required. Where anti static hoses are not available and metal connections are used then each point must be bonded, again good contacts must be achieved. Electrical connections to the equipment including must be made with either a bolted crimped lug connection or a substantial clamp arrangement. See figure below.

For each job, the equipment and conditions in which it is installed will probably be different. Therefore the precautions based on the above guidance must be considered in isolation for each job by the person responsible for the installation.








6.15 Lifting Lifting activities and the management of lifting equipment shall be in accordance with the requirements of WEL referenced documents. The Senior Mechanical Engineer is the facility Technical Authority on lifting activities. Lifting Activities Lifting of plant and equipment is a high risk activity that needs to be well controlled and planned. Lifts are classified into categories and the following table outlines the categories and the documentation required in support of lifting activities.

Classification Criteria Requirements

Routine crane operation

• Within the normal operating parameters of the crane • Lifting over non-sensitive areas • Suitable environmental conditions • Familiar, competent lifting team • Load has known and evaluated weight, shape and centre of gravity • Standard rigging arrangements • Certified lifting equipment

• Step Back 5x5 • Pre-lift meeting • Lifting Golden Safety Rules

Non-Routine Simple

• Equipment specifically installed by a competent operator • Load has known and evaluated weight • Centre of gravity below the lifting point • Use of a certified lifting point directly above the load • Ample headroom • Not within sensitive, difficult or restricted areas • Single lifting appliance • Unlikely to be affected by changing environmental conditions • Experienced and competent lifting equipment operator • Standard rigging arrangements • Suitable laydown area available

• Step Back 5x5 • Pre-lift meeting • Lifting Golden Safety Rules

Non-Routine Complicated

• Load may have an awkward shape or offset or high centre of gravity • Fragile loads or potentially unstable loads containing liquids • No lifting attachments/difficult to sling • Continuation of a lifting operation with different equipment (due to malfunction, inadequacy or unsuitability) • Continuation of a lifting operation with different personnel; for example,

• Step Back 5x5 • Job Hazard Analysis (JHA) • Specific Lift Plan approved by the site Lift Focal Point • Work Permit, if required by site permit authority • Lifting Golden Safety Rules • Pre-lift meeting





reassess JHA/lift plan at shift changeover • Use of two or more lifting appliances, including “shaking hands” • Within sensitive, difficult or restricted areas • Lifting wooden boxes using a crane

Non-Routine Complex / Critical

• Lifting of personnel/man riding operations • Over or in sensitive areas which are deemed high risk to operations/personnel • Tandem lift with two cranes • In environmental conditions likely to affect equipment performance • Load with unknown/difficult to estimate weight and/or centre of gravity • Load is special and/or expensive whose loss would have a serious impact on production operations • Mobile crane on untested / uneven ground, on moving location, on offshore installation, vessel, barge or mobile platform • Non-standard rigging arrangements • Lifts in excess of 25 tonnes • Load lowered into or lifted from a confined space • Weight of load in excess of 90% of the rated capacity of the lifting appliance (only where the lifting appliance SWL>10t) • Lifts using magnetic lifting devices

• Step Back 5x5 • Work Permit, if required by site permit authority • Lifting Golden Safety Rules • Pre-lift meeting • Job Hazard Analysis (JHA) approved by the site Lift Focal Point, with engineering input as required • Lift plan approved by the site Lift Focal Point, with engineering input as required

Lifting devices shall be operated in accordance with Woodside and legislative standards. The following guidelines are an introduction only to the safe use of lifting devices on the KGP: • Only competent personnel shall operate lifting devices and rig loads • No load shall be left suspended unless someone in control of the lifting device remains in attendance • Loads shall not be suspended from process pipework or its associated hardware • Cranes shall not be operated unless all safety devices are functional, deviations from this shall require the completion of a risk assessment approved by the site Technical Authority • Lift zones are to be demarcated with appropriate bunting and signage • Where appropriate emergency response/rescue planning is to be assessed and incorporated into the planning process • Cranes shall travel along roads with their booms down • A guide shall accompany all cranes manoeuvring in the process area • Lifting equipment is never to be overloaded. • The load is never to be attached to the point of the hook • Back hooking of chain blocks or come-a-longs can overstress swivels and must not be done





• Crane hooks shall not be overcrowded, where over crowding is likely shackles or similar shall be used • Monorail end stops shall be fitted and adequate • Chain block shall be properly secured with correct SWL displayed and in good condition Lifting Gear • Gear shall be recorded on lifting registers which include all relevant detail and certificates of conformity/current test records • All Gear shall be marked in accordance with the requirements of the Woodside Lifting equipment standard • A competent person on a regular basis shall examine all lifting gear and ensure that a record is maintained, equipment damaged or that has not been inspected shall not be used • Manufacturer serial number and safe working load should be displayed on all lifting gear • Correct keepers shall be placed on all hooks to prevent the sling from dislodging • All lifting gear shall be stored in designated areas • Slings shall not be exposed to shock loadings • Lifting gear shall be rated for the load that is to be lifted. Pad eyes or similar fixtures shall be subject to NDT prior to their use as a lift point • Slings are not to be used over sharp edges or corners without padding • Slings must not be shortened by knotting. Use the appropriate length sling

Year Month Rigging Soft slings January February March

Yellow

April May June

Yellow

Yellow Black

July August September

White

October November

2010

December

White

White Black

January February March

Blue

April May June

Blue

Blue Black

July

2011

August Green Green





September October November December

Green Black

Gin or Genny Wheels Although loads lifted in Gin wheels are typically lighter than with other forms of rigging equipment potential still exists for dropped objects and manual handling strains. Gin wheels shall be brake locking and must be installed by a competent scaffolder. It is the user’s responsibility to ensure on going fitness for service through inspection and removal after use. The area at the base of the gin wheel must be kept clear during lifting with loads not to exceed 25kg. Gin wheels must not be tied of to process equipment. Further details on lifting and hoisting can be found in the lifting and rigging handbook, document #WM1040MS3677948

6.16 Excavations Safety in and around excavations should be considered during the course of job planning, hazards created by the work scope should be identified well before excavation commences. The following requirements are designed to minimise the risks associated with excavation activity. • No excavation/penetration shall occur of any blast rated walls without engineering approval • The requirement for excavation certificates is outlined in respective permit to work / ISSOW

manuals: - Integrated Safe System of Work manual - KGP Permit to Work Manual: Part 5 - Non Operational Area

• All temporary and permanent excavations shall be barricaded (see section 6.12) • Sufficient and safe access shall be provided into, out of and across all excavations and trenches • Wherever possible a cable detector will be used to locate buried cables before excavation

commences • When the presence of a cable has been detected, or if the presence of a cable is suspected

hand digging will be used to fully reveal how the cable has been installed before continuing • Asbestos containing material slabs may be encountered during excavation activities (see section

6.18) • Starter bars or other similar up stands shall be covered with proprietary caps to protect persons • Excavations can have the potential to accumulate an unsafe atmosphere, in some cases

excavations may be managed as confined spaces. Further details on Ground disturbance standards can be found in document #W1000AF2662496

6.17 Permit to work / ISSOW Operations Area Permit to work / ISSOW procedures are intended to maintain a high level of plant safety by reducing the chance of misunderstanding when non-routine activities are planned. In the Operations area non-routine refers to anything other than the normal operation of the plant and therefore even planned maintenance is considered a non-routine activity.


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The Operations area is illustrated in the rear of this book and includes the Waste Water Treatment plant, fire water main and other facility wide reticulated services. For further clarification speak to your area Supervisor. Requests for permits shall be submitted at least 48 hours in advance. For complex activities, major maintenance and shutdown activities longer will be required. Remember If there is a site emergency all permits are cancelled the permit holder must seek advice from the Area Operator before recommencing work. PERMITS Permits are written declarations issued by the Issuing Authority to a Performing Authority which detail the nature of the work to be undertaken, the period during which the work may take place and the precautions to be taken. Permits should be considered a legal contract. Hot Work Permit Hot work permits are issued for any non-routine works in the Operations Area, which involves the use of a source of ignition. All hot work is authorised by the site controller (Operations Superintendant). Red Hot Work Permit Red Hot work permits are issued for any non-routine works in the Operations Area, which involves the use of a positive source of ignition (eg naked flame/welding/grinding). All red hot work is authorised by the Site Controller (Operations Superintendant). Cold Work Permit Cold work permits are issued for any non-routine work in the Operations area which is not “hot work”. All Cold work is authorised by the Issuing Authority (Operations Day Team Leader). CERTIFICATES Confined Space Entry A confined space is any enclosed or partially enclosed space which is not a normal place of work and where there is risk of one or more of the following being present: a) an oxygen concentration outside the safe range. b) airborne contaminant that may cause adverse health affects c) a concentration of flammable airborne contaminant above safe levels d) engulfment due to ingress of a free flowing solid or rising liquid level. The hazards of a confined space are established through the Hazard Identification Risk Assessment (HIRA) process. Entrance into a confined space must be accompanied by a valid certificate, entry means insertion of your head or breathing zone into the space. Excavation An excavation certificate is required when any ground or building walls are to be penetrated. This is a signed statement certifying that a proposed excavation can be done without risk of encountering underground cables, services or contaminated underground sites.





Operations Release Certificate A signed statement issued by a senior operator authorising removal of equipment from the Operations area. The certificate provides information on the service of the equipment and steps taken to prepare the equipment for removal from the area including any information or precautions. The certificate is duplicated the original is retained in the permit office attached to the relevant permit, the duplicate goes with the equipment. A Release tag is issued by an A.G.S.T (generally the area operator) in conjunction with the certificate and is attached to all equipment that could entrap chemicals and/or hydrocarbon that are to be removed from the operations area. Like the certificate the tag has detail on the steps taken to prepare the equipment for removal from the area. Process Mechanical Isolation Certificate This certificate shall be used in conjunction with a work permit when a process or mechanical isolation is required for work to be performed. Electrical Isolation Certificate This certificate shall be used in conjunction with a work permit when an electrical isolation is required for work to be performed. It carries details of the work activities and the controls required to manage the electrical risks of the work scope. Locking On To Isolations A locking system has been developed to maintain security and control of isolations used under ISSOW. The application of this locking system is detailed in the Woodside Guideline - Management of Isolations. Non Operations Area The Non Operations permit system is used to manage work in the Non Operations part of the plant and ensure that it is conducted in a safe manner. The issuing of a permit is at the discretion of the Area Supervisor however as a minimum the activities listed below will require a permit. • Working at heights or where a fall or dropped objects risk exists • Project or construction work • Excavation or ground breaking activities • With the exception of routine tests and checks, work that requires the isolation or inhibition of • Safety and Emergency equipment/systems • All work requiring an electrical isolation to carry out the work • Handling of substances which are hazardous to health such as Asbestos, Radioactive sources

and toxic chemicals/substances • High pressure water jetting • Abrasive blasting • Paint spraying • Removal of handrail, gratings, hatches or fixed ladders • Work involving the use of certified man riding baskets lifted by a crane • Work in any confined space, (note: Confined space work will be administered through the

Operations Permit to work / ISSOW system) • Hot work including open flames, electrical welding and grinding, (activities carried out in or in

close proximity to chemical storage, compressed gas storage and classified hazardous areas will be administered through the Operations Permit to work / ISSOW system)





6.18 Hazardous Substances To minimise the risk posed by chemicals in the workplace it is important that all chemicals are used, stored and disposed of in accordance with the requirements of their respective Materials Safety Data Sheet (MSDS) and any applicable Health Risk Assessment (HRA). MSD sheets and where applicable HRA’s shall be available at the worksite for all chemicals used. The following general rules apply: • Each workgroup shall maintain a workplace register of the chemicals used within the group • Never handle any chemical or toxic substance without being fully aware of the safe handling/

using procedure, protective clothing and equipment to be used and learn how to treat any injury that could result. This information is contained on the MSDS.

• Waste disposal of chemicals shall be according to the Karratha Gas Plant Waste Disposal Procedure L0000AH131174. Contact the site environmental officer for assistance.

Further details on Chemical approval can be found in document # L0000AH131190 Site Access for New Chemicals Approval is required to bring any new chemicals onto site, the chemical access approval process applies. Workplace Storage Chemicals must be stored in accordance with the requirements contained in the MSDS, as a general rule this will require the allocation of a dedicated storage area that permits suitable segregation distances from incompatible chemicals and ignition sources. Chemicals shall be stored so as to eliminate the risk of ground contamination and/or spillage, exposure to heat, mechanical damage, etc. Other considerations include: • Keeping minimum quantities on site required for day to day usage • Having appropriate labelling/signage and emergency response capability including fire protection

and spill mop up or containment • Making sure all chemical storage containers, including secondary containers, are clearly marked

with the contents. Note, for prescribed dangerous goods the information on the label must comply with the National Code of Practise for the Labelling of Workplace Substances.

Asbestos Containing Materials (ACM) and Synthetic Mineral Fibre (SMF) Products There are known locations of ACM on site. Asbestos containing material may be encountered in gaskets, buried cable slabs, preformed cable pits, sheeting and fire retardant cores in fire doors. The facility has an ACM register, which provides information on known locations of ACM. Asbestos Containing Materials shall be handled in accordance with the National Code of practice for the safe removal of Asbestos 2nd edition [NOHSC: 2002(2005)], copies of this guideline are available from the HS&E department. Further details on asbestos containing material can be found in the asbestos containing material register, document # L0000AF134358 Synthetic Mineral Fibres The use and handling of SMF (rockwool, fibreglass, etc) shall be in accordance with Worksafe Australia “Synthetic Mineral Fibre National Standard and Code of Practice, May 1990.

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In addition the following practices exist on site to reduce the risk posed by this material: • Waste shall be placed in plastic bags and the bags sealed prior to disposal. Materials may only

be disposed of in specially marked skips • Work practices shall minimise the release of, and exposure to fibres and dust • On-site materials shall be stored in the original packaging and in designated low traffic storage

areas only sufficient materials for daily use shall be at the work location • Work areas shall be segregated with barricades with signs stating “CAUTION SYNTHETIC

MINERAL FIBRE WORK” or “CAUTION INSULATION WORK” at least 3 metres from the installation/removal site. Other employees requiring access but not associated with the SMF installation and removal activities shall wear a P2 respirator

• Enclosures shall be used to contain fibre and dust where there are potential impacts on other work locations and when the work is aloft

• Work areas shall be cleaned regularly to prevent a build up of dust and fibres. Visible waste shall be removed promptly to avoid being trampled and spread about

• Where work on a SMF removal or installation job is interrupted for an extended period (e.g. overnight) and there is the potential for fibres to be disturbed by wind or abrasion, then the fibrous material shall be covered or wrapped to prevent the release of fibres

• Prior to entering crib rooms at approved break times personnel shall remove disposable overalls and other items of protective equipment which have been worn while working with SMF’s

• A fully charged fire extinguisher shall be kept on hand at all Poly-isocyanurate Rigid, (PIR) work faces if adjacent to other hot work activities

Radioactive Material All operators of radiation emitting devices shall be appropriately licensed and utilise work practices that remove the risk of exposure; in all cases all relevant statutory requirements and directions from regulatory authorities shall be met or exceeded. Persons working with sources of ionising radiation shall: • Obey all notices, instructions and work procedures • Report to the Supervisor any defects in equipment or procedures • Obtain approval from Plant Radiation Safety Officer to operate radiation emitting apparatus, by

having all work permits signed • Use all radiation protection devices including protective equipment and personal dosimeters in

the correct manner • Ensure radiation takes place within an area bound by bunting with a distinctive radiation symbol. • Entry into the radiation area is prohibited and nonnegotiable Further details on the management of ionising radiation material can be found in document # L0000AG132092 Nitrogen Due to the risk that its use creates, the use of nitrogen is restricted by Operations. Warning signs and segregation are used to protect people from the hazard - do not enter areas where nitrogen is being used. Nitrogen is hazardous due to it’s:

• Relative availability at utility point’s plant wide

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• Frequency of routine use for purging, sweeping and inerting activities • Odourless and colourless properties • Asphyxiant that affects the breathing trigger in the brain • Being fatal in seconds in high concentrations • Ability to asphyxiate even in an open air environment

Hydrogen Care shall be taken when working with or near compressed hydrogen. The gas is very combustible and burns with an invisible flame.

6.19 Welding/Cutting Welding and cutting activities create an obvious ignition risk that necessitates rigid controls; in addition risks of stray arcs, dropped molten metal, welding flash, (a source of eye discomfort as well as a risk to fire detection systems) and foreign body eye injuries are associated with this activity. In all cases welding activities shall be screened. In the operations area, (and other areas subject to risk assessment), enclosures constructed from non-flammable materials shall be installed to ensure complete enclosure of welding and cutting activities. Enclosures shall be of sufficient integrity to capture all sparks, molten material, metal filings/grindings and isolate from arc flash. Timber boards may be used as floor coverings of enclosures but shall be covered with suitable coverings. Ventilation shall be adequate to prevent exposure to and accumulation of fumes. Cables, leads and hoses shall where possible be routed overhead and or under walkways to protect them from mechanical damage. Cable joins shall have protective covers to prevent inadvertent arcing; and there must be regularly inspected to ensure their integrity. Earth return leads shall be connected as close to the work as possible. Flammable materials should be removed from the immediate area of hot works; fire extinguishers must be cited at the workstation in accordance with permit conditions. Gas welding equipment must be protected by flash back arresters and non-return valves are required on handsets in gas cutting/welding sets. Equipment should be isolated / closed down when not in use. The use of Acetylene on site is subject to restrictions, as it creates an explosion hazard, see section 2.4.

6.20 Manual Handling Manual handling strains can occur doing the simplest and most straight forward activities. The prevention of manual handling injuries starts with a review of the task. The weight of the load is but one consideration, other aspects to consider include:

• Frequency of task • Bending, twisting or reaching movements • Weight, size and awkwardness


• Posture and position • Distance to move • Skills and experience • Use of tools or mechanical means

Further details on manual handling can be found in the Woodside standard – Occupational Health document # W1000AF2664071

6.21 Tags

Personal Danger Tag A personal danger tag is used to identify the owner of a personal lock attached to an isolation point. They are used in conjunction with an isolation point established under an isolation certificate or on isolation points under approved “own isolation” activities. The following rules apply to Personal Danger Tags: • Can only be removed by the individual who placed the lock and tag • Can only be used when authorised on and in conjunction with a work permit • Only protect the person named on the tag • Must be completed in full • Must be removed at the end of every shift

Isolation Tags All points of isolation are indicated by tags of the appropriate type: • Orange for Electrical • Mechanical: - Red for closed valves - Green for open valves - Yellow for spades, spectacle blinds and line blanks - Red/Green for bleed check points • They carry the relevant Isolation Certificate number and isolation point reference number on the label stub and counterfoil. Under no circumstances shall equipment tagged with isolation tags be tampered or interfered with.






Out of Service Tag Prevent the operation of damaged or faulty equipment; they protect the equipment not the person who puts the tag on.

Information Tag An information tag is not to be used for any other purpose than to provide specific information on the equipment it is attached to. It is not to be used in place of an Out of Service Tag or a Danger Tag.





Operations Release Tag This tag is attached to all equipment that could entrap chemicals or hydrocarbons that are to be removed from the Operations Area to go to the Woodside or contractor workshops. The tag is affixed by an authorised person to outline the condition of the equipment including steps taken to prepare the equipment for removal from the area.

6.22 Abrasive Blasting • A minimum of two persons will be required for the abrasive blasting activities • Specific personal protective equipment for abrasive blasting shall include: - 100% cotton overalls - Leather gauntlets - Ear plugs - Air fed Blasting Helmet with air cooler • Suitable shrouding shall be erected immediately around the area where abrasive blasting is to

take place. Shrouding should be secured by rope or cable ties. Any other equipment, which may be damaged by over blast, should also be protected

• All hoses shall comply with requirements outlined in 6.8 Flexible hose assemblies • The dead-man control must be with the blaster at all times whilst blasting • Work schedules must be established to address fatigue • Bunting and warning signs should be placed around the work area so that they are clearly visible

(see section 6.12) • A visual inspection of the equipment is to be carried out at the commencement of each shift and

the prestart Operators Safety Check List is to be completed • The work area is to be left as neat and tidy as practical at the end of each shift

6.23 High Pressure Water Washing • Each HPWW activity should have contact numbers for emergency medical advice immediately

available • A minimum of two persons will be required for any HPWW job • A detailed work procedure shall be used for this activity that outlines job set up, execution and

close out of the activity. The detailed procedure shall include detail on hose management, hose security, PPE, control of water supply including emergency procedures, containment of material, minimisation of water wastage, etc

• Work schedules must be established to address fatigue • Specific personal protective equipment for HPWW shall include: - 100% cotton overalls - PVC leggings and jacket








- Steel cap rubber work boots - Gloves (gauntlet style) - Hearing protection - Eye protection. Safety glasses and face shield, (shield attached to the helmet) • HPWW hoses must be secured by a whip check at each join • The water supply line to the holding tank on the truck must be secured with a hose safety clip • Bunting and/or warning signs should be placed at strategic locations around the work area so

that they are clearly visible (see section 6.12) • A visual inspection of the equipment is to be carried out at the commencement of each shift and

the prestart Operators Safety Check List is to be completed

6.24 Spray Painting • A copy of the MSDS for each of the paints and solvents used on each job should be included in

the work pack for that job • Specific personal protective equipment for spray painting shall include: - 100% cotton overalls - Leather or cotton gloves - Balaclava and respiratory protection • Any equipment within the shrouded area that may be damaged by over spray should also be

protected • Flexible hoses used as part of the equipment shall comply with flexible hoses standards (6.8) • Bunting and warning signs should be placed around the work area so that they are clearly visible

(see section 6.12) • Health exposures shall be managed through a monitoring program • A visual inspection of the equipment is to be carried out at the commencement of each shift and

the prestart operators safety check list is to be completed • When the work is complete all masking material shall be removed and disposed of in the general

waste skips • Mixed unused paint and dirty solvents shall be returned to the site yard • Only empty solidified paint material can be placed in Blue general waste skips

6.25 Power Operate Winches Section removed, refer lifting standards

6.26 Vacuum Loading Vacuum loading of combustible products shall not occur without first being subject to detailed risk assessment which includes specifications of equipment to be used. The following general rules apply to vacuum loading: • A minimum of two persons are required for Vacuum truck operations. One must tend the vacuum

motor • Provision shall be made for breaking the vacuum should the hose operator have part of their

body drawn into the vacuum hose • Specific Personal protective equipment for Vacuum Loading shall include: - 100% cotton overalls - Leather gloves





- Suitable hearing protection • Consideration for static electricity build up must be made (see section 6.14) • Bunting and warning signs should be placed around the work area so that they are clearly visible.

(see section 6.12) • A visual inspection of the equipment is to be carried out at the commencement of each shift and

the Operators Safety Check List is to be completed • All vacuum hoses are required to have camlock fittings attached unless specified by plant

operations • The work area is to be left as neat and tidy as practical at the end of each shift

6.27 Fire Protection The nature of operations on this facility warrants the utmost respect for management of ignition sources and protection from fire. Strict controls exist over items that can be brought onto the facility and permit to work / ISSOW controls exist over hot work activities. Fire protection/fighting equipment on the facility must be maintained clear of obstruction and not be tampered with or removed from fixed locations. Work activities that require fire protection or fire control measures require comprehensive advanced planning in consultation with operations. Fire control provisions such as extinguishers and charged hoses should be arranged via operations. Additional requirements include: • All fire extinguishers shall be correctly installed and inspected regularly as required • Flammable substances shall be stored in appropriate containers in designated areas when not in

use • All used fire extinguishers are to be tagged and returned to the Fire Station for replacing • Fire watchers will be required in accordance with permit conditions Fire Watchers duties Fire watchers are responsible for ensuring the risk posed by hot work is being managed by the controls in place over the work activity and that the activity is stopped if hazardous conditions arise. Fire watchers responsibilities include but are not limited to: • Fire Watchers must have attended the Basic Fire Fighting training • Ensuring permit conditions are met • Ensuring that the welding humpy is adequate to capture all sparks. Place fire extinguishers in a

readily accessible position. Ensure that the extinguisher is the correct type for the job • Be alert and watch for fires in all exposed areas • Keep the work area clear of combustible and flammable materials • Maintain a clean and tidy work area • Keep access ways clear • Monitor changes in wind direction • Regularly check that the fire blankets are correctly positioned • Regularly check the safety of gas hoses and electric leads • Do not leave the job during hot work unless properly relieved by another firewatcher • Inspect the work area prior to leaving for the presence of any smouldering or potentially fire

creating hazards. This may require the fire watch to remain monitoring the area for a period of time after the job is complete





• Ensure work area is safe and equipment turned off before leaving the work area. Ensure that the workgroup has removed all welding stubs, spent grinding discs and other rubbish

All fires and or occurrences of smouldering and/or smoke irrespective of size must be reported to the Shift Superintendent in the CCR.

6.28 Pushbikes All KGP personnel must comply with the requirements of this section when using pushbikes on site. • All pushbikes must comply with the relevant Australian standards (AS/NZS 1927:1998) • Each bike must be fitted with at least one carry basket (either front or rear) • Reflective markers must be fitted so that the bike is visible from the front rear and sides, typically

this requires reflectors attached to the seat post, handlebars and wheels. • The person using the bike is responsible for ensuring that the bike is in a safe and roadworthy

condition prior to use • Whilst riding a pushbike the rider must wear; rated bicycle helmet, long pants and long sleeve

shirt, safety boots or shoes, gloves and safety glasses. • Bikes shall not be ridden in any construction areas • Bikes should be stored in the bicycle racks provided and must not obstruct walkways, doorways,

emergency or other equipment. If bicycle racks are not available bikes should be stored in a manner whereby they cannot fall or be knocked over or cause damage to plant or equipment

• It is the riders responsibility to properly secure the bicycle against theft Prohibited Actions • Carrying of passengers (double dinkying) • Riding with no hands on handlebars • The carrying of tools or other equipment (including drawings) in the hands whilst riding • Riding a bicycle that is damaged or unsafe • Exceeding posted plant speed limits Further details on bicycles can be found in the Karratha Gas Plant bicycle procedure, DRIMS # 6185609




7. ENVIRONMENTAL STANDARDS

7.1 General Information The Burrup Peninsular and surrounding marine waters are a unique environmental area ith a diverse range of flora and fauna that are part of a complex ecological system. In addition the Burrup is an area of significant aboriginal cultural interest. Both the environmental and cultural aspects of the area are sensitive to disturbance, and protection of these assets is an important Woodside commitment. On 3 July 2007 the Dampier Archipelago was added to the National Heritage List. This provides important recognition that some areas of the Dampier Archipelago and Burrup Peninsula contain aboriginal sites of national significance. The listing also established a boundary to allow the North West Shelf Venture’s present and future activities to occur outside the listed area. The below picture shows the listed place in green and its proximity to the Karratha Gas Plant.

7.2 Statutory Requirements The Karratha Gas Plant is defined as prescribed premises and is therefore licensed under Part V of the Environmental Protection Act 1986. The North West Shelf Venture is also subject to several ministerial approvals and conditions. Operation of the Karratha Gas Plant is conditional upon meeting strict government requirements with regards to environmental performance. As Operator Woodside is committed to complying with these requirements and has developed procedures as part of its Environmental Management System to ensure compliance is achieved.








All individuals working on the site are expected to understand and comply with KGP environmental procedures and requirements. Further information can be obtained from your line supervisor or the KGP Environmental Advisor.

7.3 Woodside Environmental Standards (WES) Woodside believes excellence in environmental performance is essential to our business success worldwide and compatible with balancing the economic, social and environmental needs of sustainable development. Woodside’s Environmental Standards (WES) aim to: • Supports the implementation of the Woodside Environmental Policy • Provides a framework for environmental decision making for our business, and • Provides detail on the environmental standards required for Woodside activities WES applies to all Woodside’s activities, including those carried out by contractors and third arties, and should be applied by all Woodside employees, contractors and joint venturers engaged in activities under Woodside operational control. Woodside’s Environmental Aspirations

Aspect Category Aspiration

Atmospheric Emissions No negative cumulative impact from our emissions to air.

Effluent Discharges No environmental impact from effluent discharges and minimal risk of other potential releases

Waste Management Hazardous and non-hazardous waste generation and disposal is managed in line with best practice

Contamination No contamination of land or impact on marine environment or fresh water resources

Resource Consumption Optimised economic and environmental performance per unit output

Social and Community Issues

Build positive sustainable contributions to the community and engage all key stakeholders

Biodiversity Activities do not impact on biodiversity and take a stewardship role in understanding and improving it

All personnel engaged at the KGP should consider if their activities are covered by or could be impacted by any of the Woodside Environmental Standards. WES is available through the Woodside intranet or by contacting the KGP Environmental Advisor.

7.4 Site Drainage & OCW Storm Water An extensive storm water system is in place for the majority of the KGP. In the LNG process storm water is collected in drains which direct the water east and then south along road 11. The water is





then directed along road 14 before passing into the administration drain and is finally discharged to No Name Bay. In the Domgas area storm water drains take water to the eastern boundary of the KGP. Hydrocarbons and chemicals must not be allowed to enter the storm water system as small quantities can lead to visible offsite contamination and breaches of environmental legislation. Remember the following: • Store chemicals and hydrocarbons away from storm water drains, site boundary and unsealed surfaces • Do not pour chemicals, hydrocarbons or wash waters into the storm water system • Permission must be sought from the shift controller for use of storm water drains for temporary storage OCW Any discharges to the OCW system must be approved by the shift controller and logged in the OCW log in the shift controller’s office

7.5 Waste Management

7.5.1 General All waste must be disposed of in an approved manner for the protection of both people and the environment. Compliance with all laws and regulations is mandatory. All chemical wastes must be disposed of in accordance with the Procedure for Disposal of Hazardous Wastes L0000AH131174, if requirements are unclear seek advice from line supervision or KGP Environmental Advisor.

7.5.2 Responsibilities The KGP waste management procedure L0000AH131174 identifies the responsibilities for waste disposal. The Waste Generator (i.e. the person who created the waste through maintenance or operational activities) is responsible for: a. Identifying waste minimisation opportunities before producing wastes b. Minimising personal exposure to hazardous materials c. Using suitable waste containers that are in good condition c. Labelling all waste containers d. Storing containers away from storm water drains e. Arranging collection and safe handling of any wastes generated c. Notifying the waste co-ordinator of hazardous waste generation The Maintenance Contracts Co-ordinator is the site sponsor for waste disposal contract and is responsible for: a. Initial processing/verification of information associated with the disposal of hazardous waste items The Environmental Adviser has responsibility for: a. Setting and reviewing waste disposal standards





b. Authorising disposal of non-standard hazardous waste items

7.5.3 Solid Waste Any waste generated on site must be managed in accordance with the “Karratha Gas Plant Waste Management Procedure”, ( DRIMS# 4945140). Some key requirements include:

• The correct segregation and disposal of waste is the responsibility of the waster generator – all waste correctly segregated is recycled.

• All waste must be labelled.

• The KGP Environmental Advisers should be engaged as early as possible to aid with correct and efficient waste management.

• Hazardous waste is not to be stored onsite for extended periods unless approval has been received from the Environmental Department.

• All waste is to be kept at a minimum distance of 3m from the Fence Line.

• Toxfree can be contacted via email [email protected] or on 0400 338 432.

Note: All skips and bins have labels for waste type.

7.5.4 Liquid Waste All liquid wastes (oils, chemicals, amines, contaminated water) are treated as potentially hazardous materials. This also includes turbine wash waters and chemical cleaning activities. Small quantities of liquid waste can be collected in suitable containers that are adequately labelled.

Waste Type Disposal Method Approval Required

Waste Oil

Emulsified Oils

Chemically contaminated water

Wash water (e.g. turbines)

Contaminated condensate

Transfer to suitable container and label with name, date, contents and source of waste.

Shift controller and/or Environmental Advisor

7.6 Oil & Chemical Spills All oil and chemical spills shall be responded to immediately. Remember the 4 C’s for action. Control, stop the loss if safe to do so. Contain, minimise the spread of the spill and keep materials from entering drains. Clean up, recover the spill using appropriate equipment.

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Communicate, complete an incident report form. If transferring oil or chemicals always maintain direct control of the operation. Do not override manual control requirements and do not leave pumps operating unattended. Priority should be given to protecting non-hardstand areas, drains and areas external to the plant. Request assistance; contact the Shift Controller in the CCR or via channel 3 if you require assistance in the event of a spill. The Shift Controller has a spill response trailer containing containment and clean-up equipment that is available in the event of a spill. All spills >1 litre should be reported via the incident reporting form, even small quantities can pose an unacceptable risk depending on the location and/or type of oil or chemical. All waste collected as a result of any clean up required shall be disposed of according to established procedures. Contaminated soil should be excavated and disposed of appropriately and backfilled with clean fill. Cleanup should achieve <100mg/kg of hydrocarbon in remaining soil. Assistance in dealing with spill cleanup can be obtained from the KGP Environmental Advisor. Discharge into the OCW system is not permitted; any discharges to the OCW system must be approved by the shift controller and logged in the OCW log in the shift controller’s office

7.7 Flora & Fauna Native fauna such as kangaroos, echidnas, monitor lizards, snakes and birds are regular visitors to site. All native fauna is protected under West Australian legislation and special permits are required to move or interfere with native species. All native fauna shall be left undisturbed unless there is danger to either the animals themselves or site personnel. DO NOT FEED native animals. Over time this can lead to increasingly aggressive behaviour which can ultimately result in attacks on personnel and necessitates the destruction of the animal. Snakes A wide variety of both venomous and non-venomous snakes are commonly found throughout the Pilbara and on the Burrup. Treat all snakes as if they were venomous, it is very difficult for the untrained observer to correctly identify the species of snake. Remember the following three points when you find a snake: • Avoid contact with the snake. Most bites occur when an untrained person tries to capture or kill a snake • Keep the snake under observation - have someone watch the snake until assistance arrives • Decide how the hazard will be managed. There are trained people on site to assist - Call the Karratha Main Gate for assistance 78171. Emergency Wildlife Carers Native animals should be left alone, in most cases the animal can rectify its situation. However specialised help is available for the care of native animals in Karratha.





If a native animal is found in distress at the Karratha Gas Plant please use one of the contact numbers below:

Animal Phone Number Kangaroo / Wallabies and Marsupials 0439 984 371

Birds / Bats 0438 924 842 Reptiles 0418 631 656

All Native animals 9182 2006 (DEC Ranger) 9185 1600 (Karratha Vet)

Feral Animals Feral cats and foxes are present on the Burrup. These introduced animals have a detrimental impact on native animals and the local ecosystem. Feral animal control programmes are regularly conducted on the Burrup by the Department of Environment and Conservation and by Woodside. To ensure that the animals are not encouraged: • Do not feed feral animals, cats in particular • Ensure all food scraps are placed in sealed bins that are not accessible to animals • Report sightings of cats on-site to the KGP General Services Manager or Burrup Services Coordinator





APPENDIX A – COVER IMAGES/ARTWORK The following references are included, they appear in the indicated locations within the pocket sized Karratha Gas Plant HSE Handbook. Event potential matrix appears inside of front cover, (WM1040MF5404904) Useful numbers and the plant map appear inside the rear cover

Useful Numbers

(Internal Phone) Emergency 90

Security gatehouse 78171

Security administration 78410

Shift Controller 78121

Senior Operators 78302

LNG 1-3 78119

LNG 4/5 78424

Domgas / Frac 78116

Services 78261

Permit desk 78496

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The our safety culture model appears on the back cover







APPENDIX B – CROSS REFERENCE TO ILLUSTRATIONS UTILISED IN THIS DOCUMENT

Karratha Gas Plant Layout http://dmslink/Link/?dmsn=6061513

http://dmslink/Link/?dmsn=6061513

Documents

Karratha Gas Plant Hse Handbook