BSWP204: TERMINAL SAFETY AND OPERATING CONDITIONS (Inclusive of Transport Driver Induction) V9 8/5/2014
OBJECTIVE: To provide clear operating instructions to ensure transport operators deliver grain correctly and safely into the Bunge Grain Terminal, this plan should be read in conjunction with the Bunge Bunbury Traffic Management Plan. SITE DESCRIPTION: The Bunge Grain Terminal (Bunbury) is a receival, storage & export facility within the Bunbury Port. Refer to Appendix A - Bunge Site Map. The Bunge Grain Terminal behind Berth 5 consists of: Sample Probes for truck sampling Receival Laboratory Automated Inward Weighbridge for gross weight (WB1) Automated Outward Weighbridge for tare weight (WB2) Road Intake Building - Drive Over Grids x 2 for grain discharge Export Laboratory Link conveyor to ship loader on Berth 3 6 x 7400t Storage Bins 4 x 700t Storage Bins Administration Office DEFINITIONS / ACRONYMS: Booking Slot The unique number describing the time and date for each delivery slot at the Bunge Grain Terminal (Bunbury) Bulk Movement Control (BMC) The terminal inventory management system Commodity Movement Order (CMO) - Bunge s reference number for an authorised movement of grain to the terminal Driver Control Station (DCS) Stations located at the Inward and Outward Weighbridge that provide messages and require confirmation of weights and / or completion of the transaction by the driver through an acceptance button Grain Quality Staff Persons responsible for sampling, testing and classifying grain Lane Indicator Lights - Lights that indicate to the driver which lane / grid to proceed to inside the Road Intake Building 2
Mass Management Code The mass limit code as listed in the RAV 2012 Heavy Vehicle Operations table used to determine the vehicle s legal mass, subject to concessions and permits Mettler Toledo Display - Screen where your weights will be displayed once your truck is positioned on the weigh bridge MSIC - The Maritime Security Identification Card required to enter the Bunbury Port Muster Points Nominated points located on a site Bunge Site Map where all persons are required to assemble in the situation an emergency siren is sounded Overhead Conveyor Gantry The conveyor that links the storage bins to the ship loader at the neighbouring site (WAPRES) Personal Protective Equipment (PPE) - Covers the list of safety gear required by drivers within the Bunge Grain Terminal RFID Card - Radio Frequency Identification - This card is collected by the truck driver at the Sample Probes. This card is deposited at outwards weighbridge before leaving site RFID Reader - Radio Frequency Identification Reader - The RFID Card is scanned on the RFID Readers which are located at the Sample Probes, under the Overhead Conveyor Gantry, Inward Weighbridge and Outward Weighbridge Receival Operator (RO) - Person in charge of selecting the grid to which the driver is to proceed. The RO has total control over the discharging operation through contact by radio to driver Road Intake Building (RIB) The building with two hoppers where drivers are required to discharge their trailers into the hopper nominated Sample Probes The two automated probes used to take samples from truck and trailer located prior to the Inward Weighbridge at the area called the Sampling Station Sampling Station The area containing the two Sample Probes located immediately prior to the Inward Weighbridge Terminal Management System (TMS) The control system for the Bunge Grain Terminal Truck Parking Bay The designated zone on Willinge Drive where trucks will park prior to entering the Bunbury Port (refer to Bunge Site Map) 3
RESPONSIBILITY Bunge s responsibility is to ensure the safe & efficient delivery of grain into the Bunge Grain Terminal located within the Bunbury Port. The driver s responsibility is to adhere to Bunge s Terminal s Safety and Operating Conditions and, when provided, adhere to instructions from Bunge personnel regarding the delivery of grain. SAFETY AND OPERATIONAL REQUIREMENTS Transport Operators (Drivers) entering the Bunge Grain Terminal are required to adhere to Bunge s Terminal Safety & Operating Conditions at all times and present themselves in a professional manner. Personal Protective Equipment required for the site includes, but is not limited to: hard hat, steel capped boots, hi-visibility long sleeved shirt or vest, safety glasses and/or dust proof goggles (where required). PART 1 TERMINAL SAFETY PROCEDURES FOR TRANSPORT DRIVERS General Directions: Drivers are required to follow the instructions issued by Bunge staff whilst they are within the terminal operational zone. This zone starts and finishes at the port entry gate. Instructions may be given verbally or in writing either by radio, SMS, visual display monitors or in person. No exhaust brakes to be used at any time in or when entering the port zone. Access to the Terminal: Normal operating hours are from 0700 to 1600 covering Monday to Friday. However, these times and days may be subject to change at any time (subject to the Terminal Manager s discretion). Drivers will be required to obtain a Booking Slot before arrival at the Terminal. Site Evacuation and Crisis Incidents: A siren will sound the alarm signalling that evacuation of the terminal is required immediately. Drivers will proceed to the Muster Point located at the entry gate of the Terminal or the emergency exit gate in the North East end of the site. Contact will be made as soon as possible with the BPA Security hut on 9729 7060 to provide them with an update on the situation. Refer to Appendix A - Bunge Site Map for muster point and exit gate locations. 4
Safety Incidents: All safety or environmental incidents will require immediate notification to the Receival Operator, the Grain Quality Staff or the nearest Bunge staff member. All incidents will need a report form to be completed prior to exiting the site. The Incident Note form can be found in Appendix C. Incident investigation may require immediate and subsequent assistance from the Terminal Supervisor (or delegate). First Aid stations are located around the site and are designated with the First Aid sign. BPA shall be informed of incidents that occur on site via Bunge. The Port Superintendent, Dave Lantry, will be the contact on 0412 100 583. Speed Limit: Please observe the 10 kph speed limit whilst within the Bunge Grain Terminal at all times. Vehicle Safety: Bunge expects all road rules to be complied with while within the Bunge Grain Terminal. This includes the safe operating and braking of vehicles, correct licensing and permitting of drivers and vehicles, adherence to GCM rules, chain of responsibility requirements and the need to manage personal fatigue. Alcohol and Drugs: Bunge has a zero tolerance policy to drugs and alcohol and reserves the right to test any driver following any incident or where Bunge staff considers the driver poses a safety risk. Random tests may apply at any time. Pedestrians: When driving through the site, please always be aware of pedestrians, especially when driving over weighbridges and the grid discharge area. Pedestrians have right of way on marked walkways. These can be found at the departure end of the Road Intake Building and around the main office. Fire Safety: The Bunge Grain Terminal is a NO SMOKING site. Several areas within the terminal are described as Hazardous Zones that are subject to dust in the atmosphere. These areas are potentially dangerous and therefore subject to stringent rules. No mobile phones are to be left switched on whilst on site. Mobile phones should be placed in the glove compartment of the Truck or vehicle at the sample station and or before entering into the Road Intake Building. The use of the 2-way radio is prohibited inside the Road Intake Building unless all doors and windows of the truck are closed and shut tight. 5
Passengers: All passengers are required to remain in their vehicle while on Bunge premises. Night Operations: When delivering at night, please remain visible to Bunge employees and stay close to your vehicle at all times. A high visibility shirt or vest with reflective strip must be worn during night operations as part of normal PPE. PART 2 - TERMINAL OPERATING PROCEDURES FOR TRANSPORT DRIVERS 1. Entry Into the Bunbury Port: Entry into the Bunbury Port requires a MSIC which needs to be obtained through the Bunbury Port Authority. The link is www.byport.com.au. A) Enter via Estuary drive and proceed past the Port Security Building observing the speed restriction of 30kph and the braking rules. Refer to Appendix B - Bunbury Port Maps. B) Drive straight ahead to the main port entry gate. C) Entry is gained by swiping your personal MSIC card at the reader which is positioned at cab height. D) Once the gate is fully open drive through observing the speed restriction of 40kph. E) Follow Port road around until you arrive at the Bunge Grain Terminal main gate on the right. F) The Port is a 24 hour export facility; other port users may be on the road at any time. Observe all road rules and courtesies. G) Observe all other port signage. 2. Arriving at the Bunge Grain Terminal After entering the Bunbury Port Authority main gate, call the Grain Quality Staff by two-way to gain permission to proceed to the Sampling Probes. The site radio channel is 17. 6
Once at the Sampling Probes, the driver will provide the Grain Quality Staff with the following 4 pieces information: A. Booking Slot Number (from Bunge); B. Commodity Movement Order Number (from Bunge); & C. The vehicles Gross Combined Mass (GCM) D. Truck Registration Number Please ensure you have this information ready and it is presented clearly to minimise errors. Re-processing may cause delays in time and/ or payments. When this information has been verified as correct by the Grain Quality Staff, the driver shall remove their tarps. Tarps shall be ground operated and the readiness of the trailers for sampling will be the responsibility of the driver. 3. Load Assessment at Sampling Station A) A RFID card is required to be collected from the collection box located at cab height adjacent to the Sample Probes. B) Once the card is obtained, the Grain Quality Staff will instruct the driver (via channel 17) to stop in the correct position for sampling so that the two Sample Probes can collect the required samples. This position is marked by a white line at the cab position of the truck. C) Scan the RFID card at the card reader station located at the Sampling Station. D) Located near the RFID reader is a red and green light that should be observed at all times. When the light is red it indicates that you must stop and ensure your truck remains in a parked position until a green light is indicated. The green light indicates that you are clear move the truck forwards onto the weighbridge. If repositioning is required the driver will be contacted via the two-way radio on channel 17. Note: Never move you vehicle when the red light is displayed. The red light indicates that you are in an appropriate position and / or the sample probes are in operation. Moving may cause damage to the probe and / or the vehicle. Driver must always wait for the green light before approaching, moving through, or leaving the Sampling Station. 7
Approach to Sampling Station Flow Chart 4. Obtain Gross Weight at Inward Weighbridge A) Once the green light at the sampling area is displayed, the driver is to wait until the Mettler Toledo Display indicates a steady weight and then drive onto the Inward Weighbridge. B) The driver is required to scan the RFID card at the card reader at the forward end of the Inward Weighbridge. This is situated to ensure that the truck is fully on the weighbridge for a correct gross weight reading. C) Once on Inward Weighbridge, the driver is to wait for a steady weight to be displayed and captured. 8
D) If the gross weight is acceptable, the driver should now accept the weight by pressing the push button located at cab height. A green light will then indicate if is OK to proceed off the weighbridge. 5. Lane Indicator Lights A) Lane Indicator Lights, located at the RFID reader adjacent to the Overhead Conveyor Gantry. A green arrow light indicates the hopper is available. B) The driver is to stop at the white line painted across the road 10 metres back from the Lane Indicator Lights. The driver must stop at this position until the Lane Indicator Light displays a green arrow to indicate the left or right grid, or for the driver to receive further instruction from terminal staff. C) You need to scan your RFID card at one of two RFID readers located at this position. Scan the reader showing a green indicator light. D) The driver can proceed towards the nominated roller door and the corresponding hopper inside the Road Intake Building. 6. Grain Discharge Procedure at Road Intake Building A) The Receival Operator will direct you by two-way radio (channel 17) to the correct position on the drive over grid. B) If the commodity mismatch check produces a positive result the Receival Operator will instruct you to drive to the truck waiting area and wait for further instruction. C) If a negative result (commodity mismatch) is produced the Receival Operator will instruct the driver to open the first trailer tailgate and raise the truck hoist to begin discharging grain. Note: Hoist must be raised in a slow and progressive manner to allow grain to flow gently into the grid. No rapid discharge will be tolerated. D) When load has been fully discharged into the grid, the Receival Operator will instruct you to lower the hoist completely. No movement of the vehicle is accepted until the hoist is completely lowered. At this point the Receival Operator may request you clean the vehicle A frame using compressed air provided, located adjacent to hopper area. 9
E) The Receival Operator will now direct you to drive forward to set your second trailer up in the correct position to discharge into the grid. Follow discharge instructions as directed in steps C & D above. F) Once the second trailer is fully discharged and lowered, and if deemed safe to do so, the tailgate will be secured by the Receival Operator. Instructions to proceed to Outwards Weighbridge will be given by the Receival Operator via channel 17 on twoway radio. Note: Movement from the Road Intake Building without clearance is prohibited. 7. Obtain Tare Weight at Outward Weighbridge A) After discharging is complete, proceed to Outward Weighbridge and wait for a steady weight to be displayed before driving onto the weighbridge. This is indicated by a green light. A red light indicates to wait. B) Once the truck is completely on the weighbridge, as determined by wheel sensors, scan the RFID card at the reader located within the Driver Control Station. C) When a steady weight is displayed, and if acceptable, press the push button to accept the tare weight and complete the transaction. D) A receipt will be printed at the Driver Control Station containing all relevant information pertaining to the delivery. E) The driver will now receive a displayed message requesting the RFID Card to be returned to the deposit box. Once the RFID card is returned to the deposit box, the driver is free to drive off the weighbridge and exit the site. Note: Priority right of way is always given to loaded vehicles entering the site. 8. Exiting Bunge Grain Terminal and Port Area A) Exit Bunge Grain Terminal through the exit gates and turn left. B) You will be required to swipe your MSIC card at the security gates in order to exit the Bunbury Port. This card reader is positioned approx 20 metres before the security gate. 10
C) Once through the gates proceed past the guard house and enter the roundabout. Note: Compliance with all Bunbury Port Authority signage is mandatory and essential. 9. Q & A: Q: How many times do I scan the RFID card at the readers? A: 4 times Where? - Sample Probes - Inward Weighbridge - Adjacent to the Overhead Conveyor Gantry (prior to Road Intake Building) - Outward Weighbridge Q: Do I keep the RFID card? A: No return it each time you leave in the deposit box at the Outward Weighbridge Q: In how many locations do I press the push button? A: 2 locations Where? - Inward weighbridge (to accept gross weight) - Outward weighbridge (to accept the tare weight / quality = completed transaction) 11
PART 3 OTHER DELIVERY INFORMATION AND KEY POLICIES Mass Management/ Overloading 1. Operation of Vehicles at Higher Mass Limits or by Permit All vehicles claiming Higher Mass Limit (HML) or Concessional Mass Limit (CML) must be accredited under the National Heavy Vehicle Accreditation Scheme (NHVAS) or the WA Heavy Vehicle Accreditation Scheme (WAHVAS), and shall display the accreditation label on the vehicle and comply with the gazette notice(s) relating to mass limit variations. Drivers claiming vehicles mass limits higher than general mass, e.g. either Concessional or Higher Mass limits or Permit Based Mass Limits, are required, if requested, to provide Bunge representatives with the vehicle s accreditation label number or relevant permit number. Drivers shall use the RAV Heavy Vehicle Operations chart and declare their mass code when requested at the Bunge Grain Terminal. At the same time, the driver will be requested to provide their Booking Slot Number and Commodity Movement Number. Failure to provide supporting evidence of the vehicle s mass limit entitlement via either NHVAS accreditation, WAHVAS and/or Permit will result in the treatment of the vehicle as operating at the General Mass Limit. 2. Driver Declaration of Legal Mass The driver is responsible for determining the vehicle s legal mass limit prior to commencing an off-farm grower delivery, after considering the following; A. Accreditations held; B. Vehicle combination used; and C. Route travelled from the loading point to the delivery site. Drivers are required to declare the LEGAL mass of their vehicle at Bunge s Grain Terminal through the application of a mass limit code. These codes are linked to the legal mass of specific vehicle type configurations, including accredited vehicles. The appropriate code is recorded on the weighbridge docket. Declaring the wrong code on a weighbridge docket and/ or exceeding the legal gross vehicle mass limit of the heavy vehicle constitutes an offence that may be dealt with by Main Roads WA or NHVR. Should you require more information on the accreditation and permit 12
schemes please contact Main Roads on 138 486 or National Heavy Vehicle Regulator on 1300 696 487. 3. Management of Overloaded Vehicles Bunge will monitor all vehicles entering or leaving its facilities. If a vehicle enters the Bunge Grain Terminal site overloaded to any extent, the weighbridge docket will be notated with a mass breach warning. To ensure worksite safety, overloaded vehicles will be assessed by Bunge staff and where appropriate the driver will be advised of additional requirements to facilitate safe management of the vehicle. Drivers are reminded that they are required to follow Bunge employee instructions at all times whilst onsite. If the vehicle is loaded on farm, both the loader and driver are responsible for ensuring the overload is corrected before the next load and are able to demonstrate that corrective actions have been taken to avoid overloads recurring. You must ensure that at all times (regardless of whether you enter the Bunge site or not), you comply with the code. The code does not provide authority for any vehicle to be loaded in excess of its statutory mass limit. Note: Special exemptions will apply for Transport Operators registered under the Harvest Mass Management Scheme (HMMS WA). Consistent with Bunge s Chain of Responsibility obligations if you enter the Bunge Grain Terminal with a vehicle: A. that exceeds its Statutory Mass Limit (overloaded) by greater than 5%; or B. you are unable to demonstrate corrective actions have been taken to manage mass in accordance with the code i.e. overload percentage trending downwards; or C. Is identified by Bunge as not conforming to the information provided to Bunge about the vehicle e.g. the incorrect legal mass is declared by the Driver, incorrect accreditation label numbers or truck registration details then The supplier/grower who consigned the load will receive a formal letter from Bunge, advising them of the breach. In addition to a formal advice letter, Bunge may also contact a supplier/grower in a timely manner by telephone, email or fax where Substantial Compliance & Enforcement (C&E) Breaches (5% to 19.9%) and Severe C&E Breaches (20% or more) are identified. Communication from Bunge will be prioritised according to severity of breach and the assessed risk of further breach. The purpose of the letter and phone call is to advise of the breach(s) so that suppliers, growers, loaders and drivers are aware and have the opportunity to implement corrective actions to ensure that further breaches do not occur. This may include altering the existing practices for loading and delivery of grain to Bunge s Grain Terminal. 13
Harvest Mass Management Scheme (HMMS) Note: Bunge is not yet registered for this scheme The HMMS only applies to grain transported from a paddock to a registered grain receiver during the defined harvest period. As a registered grain receiver, Bunge Grain Terminal has an agreement with Mains Roads to establish and apply the rules of HMMS. Transport Operators choosing to work under HMMS will be required to register in the scheme with the Bunge Grain Terminal. In order to register for the scheme, you will require your vehicle s Gross Vehicle Mass (GVM), Gross Combination Mass (GCM), steer and drive. The HMMS will provide an extra mass allowance for registered scheme participants. A harvest mass allowance of up to 10% above regulatory mass limits (to a maximum of 10 tonnes) will apply for vehicles meeting the scheme requirements. This 10% allowance applies to both the vehicle s gross mass limit and the axle or axle group mass limits. Action will be taken against any vehicle that exceeds the scheme gross or axle mass limits. The HMMS is modelled on a load rejection concept. In the event of a grain load being presented that exceeds the HMMS allowance, the load will be deemed non-compliant and the onus will be on the Transport Operator to take corrective action to ensure the load complies with the rules of the HMMS scheme. Options available for corrective action: A. Correct the load out of Bunge premises and re-present to the Bunge Grain Terminal. B. Forfeit the grain to the scheme that is in excess of the HMMS mass limit or Acceptable Vehicle Mass (AVM). The Transport Operator will be allowed 5 strikes for loads exceeding the AVM before membership to the scheme is suspended for the remainder of the harvest. Refer to Bunge Grain Terminal s HMMS Procedures document (under construction as at March 2014) that covers the procedures related to the scheme. Load Grading For the classification of grain, Bunge s Grain Quality staff use the receival standards developed by the industry and established by the Grain Industry Association of Western Australia (GIWA). 14
Tailgate Policy Due to the dangers of opening truck tailgates, all tailgates are to be opened and closed by the driver. However, if the Grid Receival Operator deems the rear-most tailgate safe, the Grid Receival Operator will close this tailgate. Minimum Truck Configuration In order to maintain the efficiency of the site, and subject to legal mass limits, truck configurations shall carry grain no less than a minimum payload (nett) of 50 tonnes. Contaminated Loads Deliveries containing any NIL tolerance defects and contaminants will be rejected. Examples of such defects/contaminants include: Contaminants List Pickled grain Animal residue or excreta Coriander Chemical residues Musty grains (oats, barley) Crow garlic Storage mould Live stored grain insects Metal Tainted grain Phosphine Declared weeds Ball smut (wheat) Glass Sticks Head damaged and bin burnt Fertiliser Stones (wheat) Dryacide treated grain Dyed grain Manual Receivals In the event that the automated systems and / or computers are not available or otherwise down, then deliveries will be classified using a manual system. Delays may be experienced in such a scenario. Multi-Load Deliveries Bunge does not accept multi-load deliveries. For clarity, each trailer of one truck configuration shall have the same grade of grain, for example, two trailers of APW, two trailers of feed barley etc. 15
Weighbridge Tickets The weighbridge ticket provides the confirmation that grain was received into the terminal. The ticket will include the following information: quality, quantity, type, variety and grading. At the Outward Weighbridge, please check the delivery information on the screen before accepting the transaction via push button. Dispute Resolution Process Where a driver or supplier disputes the quality assessment derived for a certain delivery, the result can be disputed or taken up with the Grain Quality Staff who will discuss the options available. 16
APPENDIX A BUNGE SITE MAP 17
APPENDIX B BUNBURY PORT MAP Proposed Bulk Haulage Route 18
APPENDIX C - INCIDENT NOTE 19
APPENDIX C INCIDENT NOTE- CONTINUED 20