Hobart Procedure

Personal Risk Management:

Personal Pre Starts & JSEAs HP-854-03709

1. Overview

One element1 of risk management at Nyrstar Hobart (NH) is Personal Risk Management. Personal Risk Management is the process that must be used by employees and contractors to manage the day-to-day risks they face as individuals and work groups. Personal Risk Management is simply the act of adhering to the Golden Rules. The Golden Rules state:

1. Everyone on site must complete a Personal PreStart for every job they do.

2. If the job’s risks are greater than ‘low’, the job must have either a Standard procedure or JSEA. If not, the job can’t start!

3. Everyone required to complete a job that is subject to a JSEA must have a ‘Work Permit Clearance Certificate’

4. Everyone intending to complete Defined Hazardous Work must first have a ‘Work Permit Clearance Certificate’.

The scope of this document is limited to the completion of Personal PreStarts and JSEAs.

2. Purpose

This document applies to all employees and contractors at NH.

This document defines the responsibilities of various employees and contractors in respect of Personal PreStarts and JSEAs.

This document describes the purpose and use of the Personal PreStart process (including the use of the Personal PreStart Notebook), and the methodology for completing a JSEA.

3. Definitions

ALARP As Low As Reasonably Practical. A level of Residual Risk that is not necessarily tolerable to the organization, but reflects that the extent of risk reduction measures that have been undertaken are those that can be justified by a cost-benefit analysis.

Hazard A source of potential harm or a situation with a potential to cause loss.

JSEA Job Safety Environment Analysis.

Risk The chance of something happening that will have an impact on objectives. It is measured in terms of consequence and likelihood.

Frequency A measure of the rate of occurrence of an event expressed as the number of occurrences in a given time.

Consequence The outcome of an event expressed quantitatively or qualitatively, being a loss, injury, impact, disadvantage or gain. There may be a range of possible outcomes associated with an event.

1 A description of complete risk management model at Hobart is provided in the Hobart ‘Management System Manual’ HP-934-00266 , whilst risk management pertaining to safety is presented the Safety Management System Manual HP-852-02854.

Likelihood A qualitative description of probability or frequency.

Residual Risk Risk assessed after a consideration of the controls currently in place to reduce or mitigate the potential for an event. These controls may serve to reduce the consequence or the likelihood of the event.

Inherent Risk Risk associated where there are no controls in place to manage or mitigate the potential for an event.

Nyrstar Representative An authorised Nyrstar employee appointed to the role that is accountable for managing all aspects of the work team. They may authorise others to act as delegates.

Standard Procedure (SP) A Standard Operating Procedure or Standard Maintenance Procedure.

Defined Hazardous Work (DHW)

Specified types of work that require additional risk assessment and authorisation prior to the task being carried out. DHW includes:

» Confined Space Entry

» Hot Works

» Working at Heights

» High Reach

» Hazardous Area Entry

» Excavation / Break In

» Working on Radioactive Sources or Gauges

» Isolations not covered by PTW database

» Electrical Isolation

» Energised Work

» Demolition Work

» Use of Restricted Tools and Equipment

Risk Scenario Describes how the hazard leads to the risk.

4. Responsibilities

4.1. Employees and Contractors

Every person working on the NH site is required to answer the questions and complete the actions specified in the Personal Risk Management Process. The overarching rule in applying Personal Risk Management is; if you’re not sure, ask!

Every person working on the NH site must complete a ‘Personal PreStart’ before they start each & every job.

Every person working on the NH site must carry on his or her person, a Personal PreStart Notebook.

4.2. Nyrstar Representative

An authorised Nyrstar employee appointed to the role that is accountable for managing all aspects of the work team. They may authorise others to act as delegates.

4.3. Contractor Supervisor

A Contract Company employee(s) who are responsible for all work their company is undertaking on site. A Contractor Supervisor or delegate MUST be involved in the preparation of any JSEA that involves work being undertaken by their firm.

4.4. Work Area Owner

The Nyrstar Team Leader / Process Leader who is accountable for the work area but is not a member of the work team (or their delegate, as designated by the Department Superintendent).

A Work Area Owner or delegate MUST be involved in the preparation of any JSEA that involves work in their department.

4.5. Job Representative

A Nyrstar person or contractor who is responsible for all members of the work team and ensuring all work is completed as per site procedures. They must be a member of the work team and be present for the duration of the task.

5. Personal Risk Management

Personal Risk Management is simply the act of adhering to the Golden Rules. The Golden Rules state:

1. Everyone on site must complete a Personal PreStart for every job they do.

2. If the job’s risks are greater than ‘low’, the job must have either a Standard procedure or JSEA. If not, the job can’t start!

3. Everyone required to complete a job that is subject to a JSEA must have a ‘Work Permit Clearance Certificate’

4. Everyone intending to complete Defined Hazardous Work must first have a ‘Work Permit Clearance Certificate’.

Anyone can adhere to Personal Risk Management process by answering the questions and completing actions set out in the following flow diagram. Remember, when applying Personal Risk Management process, if you’re not sure, ask! The act of answering these questions is the Personal PreStart.

You've beenassigned a task

Start Job, afterplacing Tags andLocks if required

Complete a JSEAObtain Work

Permit ClearanceCertificate

Does the taskinvolve any DefinedHazardous Work?

Think About theHazards

Is the job's ResidialRisk LOW?

NO

Is the task covered bya StandardProcedure?

Is the task covered bya StandardProcedure?

Apply the StandardProcedure if there

is one

NO/Not Sure NO/Not Sure

YES

NOYES/Not Sure

YES

YES

Apply the StandardProcedure

Apply the StandardProcedure

Obtain a DHWAuthorisation

6. Personal Pre Start

6.1. Overview

The Personal PreStart has two purposes:

» To ensure everyone working on site considers the hazards in their work environment, assess their potential risk, and take steps to control the hazards.

» To remind everyone working on site about the questions and actions associated Personal Risk Management process and provide a tool to aid its application.

Every person working at NH must complete a ‘Personal PreStart’ before they start each & every job.

Every person working at NH must carry a Personal PreStart Notebook with them at all times.

6.2. Using the Personal PreStart

Obtain a Personal PreStart Notebook.

To do a Personal PreStart there are four questions to ask yourself:

1. Am I clear on what the job involves?

If the answer is ‘yes’, then you ask yourself Question 2. If the answer is ‘no’, then the person is required to speak to their Nyrstar Representative and not start the job until you can answer ‘yes’ to the question.

2. Does the job involve any ‘Defined Hazardous Work’?

If the answer is ‘yes’, then you must ensure that there is either a JSEA or Standard Procedure covering the job as well as a WPCC for the job. If you don’t have these documents, you must not start the job.

If you are unsure of the answer, or you are not clear of what is meant by the term ‘Defined Hazardous Work (DHW), then you must speak to your Nyrstar Representative and not start the job until you can answer the question. (The list of DHW is listed in your Personal PreStart Notebook.)

You must then ask yourself the next question:

3. Are there any hazards present today not covered by the JSEA or standard procedure, or if there is no JSEA or standard procedure for the job, are there any hazards present today?

» If the answer is ‘yes’ to either part of this question, or you’re unsure as to the answer, you must answer question 4. If you are sure the answer is ‘no’, then you should carefully proceed with the job.

4. If there are Hazards, is the Residual Risk low?

Before answering question 4, you must first identify the potential hazards associated with the job. You are encouraged to review the hazard identification table in your Personal PreStart Notebook and use the Personal PreStart Notebook to list the hazards, the potential consequences of hazard, and how you’ll control the hazard. For further guidance refer to Appendix 10.1 and speak to your Nyrstar Representative.

Next, and before answering question 4, you must determine the Residual Risk associated with each hazard. This is done using the Nyrstar Risk Table located on the back cover of the Personal PreStart Notebook. For further guidance refer to Appendix 10.1 and speak to your Nyrstar Representative.

If you are sure the answer is ‘yes’, then you should carefully proceed with the job. If the answer is ‘no’ (i.e. you think the risk may be greater than ‘low’), or you’re unsure as to the correct answer, then job may not proceed until you have spoken to your Nyrstar Representative, and you have an approved standard procedure, JSEA or other approved risk study. Guidance on the tolerability of risk and management of hazards is provided in Appendix 10.2.

Note: If you are ever unsure of the answer to any question, speak to your Nyrstar Representative. For most employees, the Nyrstar Representative is your Team Leader.

By answering the four questions you are doing a Personal PreStart. There is no requirement to write your answers to the questions in the notebook but you should be able to discuss your answers to the questions if asked.

7. Job Safety Environment Analysis (JSEA)

In completing a Personal PreStart you may be required to complete or obtain a JSEA.

A JSEA (HF-854-03655) is to be used for assessing work when:

» The task has a residual risk rating of greater than LOW and there is no standard procedure for the task.

» The task involves DHW and there is no standard procedure for that work.

To perform a JSEA a team should be used, comprising:

» Work Area Owner.

» Contract Supervisor (if a job being performed by Contractors).

» Any other people with knowledge of the work area or task, as identified by the Nyrstar Representative.

Section 1 of the JSEA must show the following information:

» The description of the task.

» The department where the work is being completed.

» The specific work location.

» The name of the Work Area Owner, Contract Supervisor (if applicable) and any other people involved in the JSEA.

» The Contract Companies involved in the JSEA (if applicable).

» The Nyrstar Representative name, signature and contact number.

» The Job Representative name, signature and contact number.

Section 2 of the JSEA is the Hazard Identification Table that is used to carry out an analysis of the job steps. This table indicates both work area and task hazards.

Next an analysis of the job steps is to be carried out. Information required includes:

» The Basic Job Steps.

» Any potential hazards associated with the job steps.

» Any current controls in place to reduce the hazards that were identified.

» The consequence and likelihood and associated risk rating of the hazards.

» Any additional controls that can be put in place to lower the risk rating.

» The final consequence and likelihood and associated risk rating of the hazards.

The consequence, likelihood and risk rating tables are shown on Page 4 for reference.

The highest risk rating is to be indicated. This is the highest risk rating on the analysis of the job steps after ALL controls have been put in place.

Any DHW associated with the task is to be indicated.

Isolations required are to be listed by the Work Area Owner.

The Job Representative is also required to identify how the content of the JSEA will be communicated.

The final page of the JSEA is the acknowledgement of the contents of the JSEA by all people working on the task. Each person will need to read and understand the JSEA and place his or her name, signature and date the document.

8. References

ZP-EXSD-00026 Sustainable Development Risk Assessment

HF-854-03655 JSEA Form

HP-854-03718 Defined Hazardous Work Standard

9. Appendix

9.1 Risk Assessment

9.2 Risk Tolerability and Hazard Management

Appendix 9. 1

RISK ASSESSMENT

Risk Assessment Process

A risk assessment is a process whereby the probability of an unplanned event happening (when all the normal procedures and processes are in place) is measured against the magnitude of the consequence, should an incident eventuate.

The probability and magnitude of the consequence is measured against pre-set criteria, parameters or severity. The more often there is a chance of an incident, and / or the bigger the damage bill as a result of the incident, the higher the risk rating.

The risk rating may be used to identify those things, which pose an acceptable risk, those that require immediate attention, and those which must be placed in priority order as a part of a programmed. The probability and magnitude criteria are termed likelihood and consequence.

The likelihood of events occurring and the magnitude of their consequence must be evaluated in context of their existing controls and the value assigned as part of a risk assessment score is also based on judgments and assumptions.

If you are unclear on these ideas, you must speak to your Nyrstar Representative.

Step 1 - Determining the ‘Likelihood’ of event

Likelihood refers to the chance of an incident recurring given that all relevant controls are in place. It is important to consider:

Number of times the job is undertaken (frequency).

The total period of time to which all employees or the environment is exposed to the hazard (duration).

The probability of people or the environment being exposed to the hazard WHILE CONTROL MEASURES ARE IN PLACE.

Having considered these things, use the table below (as reproduced on the back of your Personal PreStart Notebook) to select a Likelihood classification.

Step 2 - Determine the Consequence

To decide on a ‘credible’ consequence, imagine that the event occurred a 100 times (irrespective of how unlikely that event may actually be), and use the table below to select a consequence classification.

Step 3 - Calculate the Risk Rating

Use the likelihood and consequence classifications from determine the risk rating from the table below. If you’re unsure how to do this, ask your Nyrstar Representative.

At the end of this process you should have a risk rating e.g. High 15

Appendix 9. 2

RISK TOLERABILITY & HAZARD MANAGEMENT

Risk Tolerability

At NH you may only proceed with a job if:

The residual risk is low, or

The job’s risks are greater than low, if the hazards are managed by means of an approved Standard Procedure or JSEA.

The level of approval required for a standard procedure is determined by the magnitude of the risk to be managed. The level of approval required is determined using the Risk Approval Matrix. (e.g. a standard procedure that is used to manage a risk with a residual rating of ‘High’ requires a Superintendent’s approval).

RISK APPROVAL MATRIX

Residual Risk Rating Risk Assessment Type Required Approval Required

Low Personal Pre-Start Self

Moderate JSEA Team Leader

High Structured Risk Analysis (e.g. HAZOP, SWIFT etc).

Superintendent

Extreme Structured Risk Analysis (e.g. HAZOP, SWIFT etc).

Manager

The table above details the type of risk assessment required at each risk level, and the approval required prior to work commencing. This table is also presented in the Personal Prestart Notebook.

Where a JSEA for a job reveals that the risk is greater than ‘Moderate’ or greater, a HAZOP or other high-level risk assessment may be required. In these circumstances, you are required to speak to the Nyrstar Superintendent responsible for the work area (after speaking to your Nyrstar Representative first).

Note: A Manager prior to commencing the task must approve any task that potentially has a consequence of ‘Major or Catastrophic’. For assistance in determining level of risk assessment required, refer to SHEQ Department

Hazard Management

Hazards that pose a risk of greater than ‘low’ must be managed.

In managing hazards NH requires its staff and contractors to apply the ‘Hierarchy of Controls’ as per the table below.