Molten Materials Processing and Handling Major Hazard Standard

Transcription

1 WMC Environment, Health & Safety Management System Molten Materials Processing and Handling Major Hazard Standard MHS-04 DocsOpen Ref: 55948, 04/09/2001 Uncontrolled copy check web for latest revision Revision Reviewed Description of Changes Date Approved 1 A Barfield Revised 04/09/2001 P Plavina 0 First Issue 12/07/2000 K Thomas WMC Resources Ltd WMC has developed this document for internal use, specific to circumstances and conditions within its operations. It is intended to provide general information and its applicability to external parties may therefore be limited. WMC makes no representations as to the applicability of the information for use by any party other than WMC and should not be relied upon as such. WMC provides no representation or warranty as to safety or business outcomes arising from application of this document and its requirements by third parties.

2 Molten Materials Processing and Handling PURPOSE AND SCOPE...2 DETAILS Risk Management Strategy Design of Molten Materials Processing and Handling Facilities Conceptual Design Detailed Design Procurement Construction and Commissioning Operating the Molten Material Facility Standard Operating Parameters Cooling Water Circuit Standard Work Procedures Maintenance Management Requirements Decommissioning and Disposal of MMPH Facilities...4 APPENDICES...5 A Definitions...5 B Related Documents...5 C Revision Information...5 Standard Coordinator: A. Hunt EOF Coordinator: K. Thomas Group Manager - Safety & Health: S. Klyen SAF-MHS-04 Rev. 1 Docs: Issued: 18/05/99 Page 1 of 7

3 PURPOSE AND SCOPE The purpose of this Standard is to eliminate molten material related fatalities or serious injuries. This Standard applies to all molten material systems from the design stage of a facility through construction, commissioning, operation and maintenance to the final decommissioning stage. DETAILS 1 Risk Management Strategy Formal risk assessment techniques shall be used to reduce the risks in Molten Materials Processing Handling (MMPH). The risk assessment shall identify as a minimum: All sources of molten materials Exposure of people to risk from molten materials Explosive emission from containment Spills and run outs Transport collisions. The management systems at the facility shall minimise the probability of: Exposure of people to risk from molten materials Explosive emission from containment Spills and run outs Transport collisions. In order to continually improve the process, the objectives of management should be to: Remove the need for water near molten material Remove the need for people to be adjacent to the tapping process Remove the need for people to be exposed to molten material. To achieve the above stated objectives, management shall apply the risk assessment techniques to all areas from the initial concept through final design and operation to the decommissioning stage of an MMPH facility's life. A change management system shall be developed at each facility that ensures that changes in design, maintenance, work methods, and operating parameters do not prejudice the safety or integrity of the MMPH facility or its operators. 2 Design of Molten Materials Processing and Handling Facilities There shall be a requirement on the designers of a Molten Material Processing or Handling facility to minimise the exposure of personnel to molten material and heat stress. The design stage has two phases. These are the development of the concept and the development of the detailed design. 2.1 Conceptual Design The person proposing a new MMPH system shall lodge a formal notification of the concept to the General Manager or his delegate. Included in this notification shall be a conceptual layout of the proposed system, a risk assessment and the justification. The concept shall be reviewed using the engineering and commercial approval systems. The proposal shall address the following areas: Chosen process route Chosen technology Handling systems Cooling system requirements Building layout and organisation Emergency response provisions Operational and maintenance requirements Construction plan Project management plan Project budget. Once the concept is approved, significant changes shall not be made without further full review and risk assessment. 2.2 Detailed Design The General Manager shall appoint a competent person or group of people as an Approving Authority for the design of the MMPH system. Engineering specifications shall be developed for each MMPH project. These specifications shall identify which processes involve the presence of Molten Materials and how the inherent hazards will be controlled. Critical items shall be identified and their tolerances specified. Water supply to cooling water circuits shall be designed to have the highest level of passive safety. Water shall be supplied via a gravity system with a reserve capability in the event of a power failure. The amount of reserve capacity required shall be determined for each site. SAF-MHS-04 Rev. 1 Docs: Issued: 18/05/99 Page 2 of 7

4 All designs shall be subjected to formal design risk assessments, the results of which shall be documented. Before approving the detailed design, the Approving Authority shall complete a formal review of the engineering specifications and the design risk assessments. 2.3 Procurement Each site shall ensure that changes to the design or the specifications of materials cannot be made without a formal review to ensure that the safety of the MMPH is not prejudiced. Appropriate quality assurance procedures shall be in place to ensure that equipment and materials are supplied in accordance with specifications. 2.4 Construction and Commissioning During the construction and commissioning phases the competencies and training requirements of all employees on site shall be confirmed. Sites shall develop an appropriate induction for the members of the construction and commissioning teams. This induction shall ensure that all persons required to work in the vicinity of molten material areas are aware of the potential dangers and are deemed competent. Prior to commissioning the site shall identify the necessary competencies, equipment and methods to deal with a loss of containment of any molten material. During commissioning, access shall be strictly controlled in areas where molten materials could be encountered. Only competent staff shall be allowed inside the restricted areas. 3 Operating the Molten Material Facility 3.1 Standard Operating Parameters Standard operating parameters shall be set for all facilities. A formal risk assessment shall be carried out prior to approval for the facility to be operated outside the standard operating parameters. These parameters shall include, but not be limited to: Slag/metal/matte temperature Slag/metal/matte composition Furnace wall or gas temperature Feed rate Discharge rate (product and slag) Percentage of oxygen in combustion gas Cooling water usage Cooling water temperature Inlet/outlet gas temperature Bath level and freeboard. 3.2 Cooling Water Circuit Sites shall develop and implement a procedure for dealing with the loss of water supply. Safe work procedures shall be in place that detail the actions required in the event of a water leak into or around the MMPH facility. 3.3 Standard Work Procedures Standard Work Procedures (SWP) shall be developed for all activities where molten material is likely to be encountered. These shall include, but not be limited to the following: Response to MMPH loss of containment situations Safeguarding vehicles in MMPH activities Tapping molten material from furnaces Cooling water management Specifications and provision of personal protective equipment Control of charge materials Provision of competence to persons working in MMPH activities Transfer of molten materials Safe operation of casting machines Safe operation and maintenance of launders Safe operation and maintenance of molten materials ladles Safe operation and maintenance of granulation facilities Safe operation and maintenance of molten material disposal sites Safe operation and maintenance of furnaces Safe use of liquid and gaseous fuels in furnaces and ladles Safe repairs on a working furnace Housekeeping in molten materials areas Emergency isolation of services in molten materials areas Blasting in an operating furnace. All relevant employees shall be trained and assessed for competence in these procedures. SAF-MHS-04 Rev. 1 Docs: Issued: 18/05/99 Page 3 of 7

5 4 Maintenance Management Requirements The site Maintenance Management system shall include the use of a risk assessment process to identify critical components and their required maintenance activities. There shall be a schedule for the maintenance activities at the facility. Production pressures shall not cause critical maintenance work to be delayed or deferred without a formal risk assessment. SWPs shall be drawn up for all routine maintenance activities where molten materials may be encountered. Staff competency is to be assessed. A Job Safety Analysis shall be completed prior to any non-routine maintenance activity in a MMPH area. 5 Decommissioning and Disposal of MMPH Facilities Prior to any decommissioning or disposal activities, a risk assessment shall be conducted. Detailed plans and SWPs shall be drawn up to ensure that equipment or facilities are decommissioned or disposed of in a safe manner. Decommissioned plant shall be maintained in a safe condition. SAF-MHS-04 Rev. 1 Docs: Issued: 18/05/99 Page 4 of 7

6 APPENDICES A Definitions Abbreviations MMPH B Related Documents None C Revision Information This is the second issue of this Standard. Revision 1 issued 12/05/99 Revision 0 issued 31/10/97 Differences from the previous revision are: Section (Existing) Difference Changed all must and will to shall. Changed all Resident Manager to General Manager 1 Risk Management Strategy Paragraph 2 rewritten. Added new bullet list following The management systems at the facility Added new last paragraph A change system. 2.1 Conceptual Design Added new bullet 2 to list. 2.2 Detailed Design Added new paragraph Water supply to 3.1 Standard Operating Parameters 3.2 Cooling Water Circuit Reworded paragraph 1. Reworded paragraph 1. SAF-MHS-04 Rev. 1 Docs: Issued: 18/05/99 Page 5 of 7

7 Section (Existing) 3.3 Standard Work Procedures 4 Engineering and Maintenance Requirements Difference Added new bullet 4 to list. Retitled section to Maintenance Management Requirements 5 Decommissioning and Disposal of MMPH Facilities Added new paragraph 1. Reworded subsequent paragraphs. Added new first and last sentences. Reworded existing sentence. SAF-MHS-04 Rev. 1 Docs: Issued: 18/05/99 Page 6 of 7