General Site Safety Rules Rev 21

General Site
Safety Rules
REVISION #21
ALUMINIUM METAL
PRIMARY PRODUCTION KURRI KURRI
Dear Inductee,
Welcome to the Hydro Aluminium Kurri Kurri General Site Safety

Induction. Please take a few minutes to read the information on this page -
it just might help you!
Q: How do I "pass" the induction?

A: The simplest and easiest way to be successful on your first attempt at
the induction is to READ THE HANDBOOK and complete the "Self
Test" questions contained at the end of each section. Experience has
shown that people who do not read the handbook do not pass the
induction. If you want to avoid the hassle of sitting a retest, then
READ THE HANDBOOK.
Q: What do I need to bring with me to the induction?

A: You will need to bring the following items to the induction:
1. Your copy of the "General Site Safety Rules" Handbook
2. Photo identification (eg. drivers licence, passport)
3. Your WorkCover certificates (if applicable)
If you do not bring all of these items with you, then you may be refused the
right to undertake the induction and required to book in again to do the
induction on another day.
Q: What will happen if I do not "pass" the induction?

A: If you do not pass the induction on your first attempt you will be
required to book in at the Gatehouse to redo the assessment. Retests
are generally held at 6.30 am, Monday to Friday.
Q: What do I need to bring with me to the retest?

A: You will need to bring your photo identification (eg. drivers licence,
passport). If you do not have an acceptable form of identification with
you, then you will not be permitted to do the retest.
Q: What if I don't "pass" the retest?

A: If you do not pass the induction on your second attempt you may be
required to undergo the entire induction process again. So make sure
you READ THE HANDBOOK to avoid this happening to you.
Good Luck!
Hydro Aluminium Kurri Kurri Pty Ltd
CONTRACTOR SITE INDUCTION DETAIL FORM
ID NO: ________ CARD NO: ________ PASSPORT NO: __________

GIVEN NAMES: ______________________________________________
SURNAME: ___________________________________ SEX: ___
DATE OF BIRTH: __________________________
YOUR ADDRESS: _____________________________________________
_________________________________________POSTCODE _________
HOME PHONE: ______________________ MOBILE NO: ______________
CONTACT PERSON (FOR EMERGENCIES): __________________________
EMERGENCY PHONE NUMBER (S): ________________________________
COMPANY NAME: _____________________________________________
COMPANY ADDRESS: __________________________________________
POST CODE: _________________
COMPANY PHONE NUMBER: _____________________________________
YOUR JOB CLASSIFICATION: ____________________________________
HYDRO DEPARTMENT: __________________________________________
HYDRO SUPERVISOR: __________________________________________
WORKCOVER TICKETS HELD: ____________________________________
WORKCOVER LICENCE NUMBERS: _________________________________
Statement of Agreement:
I, the undersigned, have reviewed and understand the information
contained in the Hydro Aluminium Kurri Kurri Pty Ltd General Site Safety
Rules and agree to conform to the requirements outlined in the booklet.
The information I have provided regarding my personal details is, to the
best of my knowledge accurate.
Signed: Date:
Office Use Only

Were ALL critical questions given a 3 - Yes / No
Applicant is: Competent Knowledge
Not Yet Competent
Comments/Feedback (Assessors to make any additional comments which

clarify the assessment).
Date of Assessment: _____________________________

CONTRACTOR SITE INDUCTION DETAIL FORM
ANSWER SHEET
ASSESSMENT NO: ASSESSED BY:
C.1. C.6. C.11. C.16. C.21.
A. A. A. A. A.
B. B. B. B. B.
C. C. C. C. C.
C.2. C.7. C.12. 17. 22.

A. A. A. A. A.
B. B. B. B. B.
C. C. C. C. C.
C.3. C.8. C.13. C.18. C.23.

A. A. A. A. A.
B. B. B. B. B.
C. C. C. C. C.
4. C.9. C.14. C.19. C.24.

A. A. A. A. A.
B. B. B. B. B.
C. C. C. C. C.
C.5. 10. C.15. C.20. 25.

A. A. A. A. A.
B. B. B. B. B.
C. C. C. C. C.
APPLICANT'S SIGNATURE: DATE:
ASSESSOR'S SIGNATURE: DATE:

GENERAL INSTRUCTION
1. Review and understand the contents of this booklet before you

undertake the site 'General Induction'.
2. If you are a contractor, complete the Contractor Site Induction detail

form and sign the statement of Agreement. Employees will be provided
with a separate form.
3. Bring this booklet (and completed form as per point 2) to the site
'General Induction'
Remember all the requirements

outlined in this booklet are designed
to protect the health, safety and
wellbeing of all persons on site.
O ur G o al i s ZERO
- Z ER O I nj ur ies
- ZERO Defects
C O N T E N T S
I nt ro d uct io n
Safety at the Sme l te r 1
Se ctio n No 1 T he Induct ion S yst em

The Ge ne ral Site Safe ty Induction 2
T he P as s B o ok 3
Visitors 4
W h a t t h e G e ne r a l Sit e Saf e t y I n d u c t i o n D oe s N o t C ov e r 5
W h a t Work t he G e ne r a l S it e S a f e t y I nd u c t ion W il l N o t Le t Y o u D o 6
Re v is ion 7
Se ctio n No 2 Pro hi bited & Re stri ct ed Arti cle s

What Items Are Prohibited on Site 8
What Items You Can Bring on Site 10
What Items Need Wri tte n Pe rm is s ion t o be All owed on Site 11
Re v is ion 12
Se ctio n No 3 S melt er Safet y Po li cy & Proc eed ing s

Sm elte r Occupational He alth a nd Safety Policy 13
H y p e r -Re a c t iv e A i r w a y s o r A s t hm a 14
W h o is r e s p o ns ib le f o r s a fe t y a t t he Sme lte r 15
Safe Behaviour Observance 15
Safety Sampling 16
D uty of Car e 16
Risk Manageme nt Sy stem 17
I n c id e n t R e p o rt ing 18
N e a r M is s Haz a r d R e p o rt ing 19
Re v is ion 20
Se ctio n No 4 PPE - Housekeep ing & S mo king, Drug s,

Alco ho l
What Personal Protective Equipment [PPE] Must Be Worn at Work 21
Ge ne ral House keeping 22
No S m ok ing P olicy 23
Al c ohol and Ot he r D rugs P olic y 24
Re v is ion 25
Se ctio n No 5 E merg enc ies, First Aid - PEO

E me rge ncy P ro ce dur es 26
T he P lant Em e rge ncy O r g anisat ion [P EO ] 27
H o w t o R ai s e A n A lar m 28
What to Do If You He ar An Alarm 29
Fires 30
F i r e Ex t i ng u is h e r s 31
W ha t Are t he E v ac uat io n P r oced ure s F or t he Sm elt er 32
Fi r st Ai d F a ci lit ie s 33
Injury Manageme nt and Re habilitation 33
Re v is ion 34
Se ctio n No 6 S igns
Re d 35
B l ue 35
Ye llow 36
G re e n 36
Re v is ion 37
Se ctio n No 7 Sa fet y Fo r V ehicle Dri ve rs & Pede strians

Ve hicles on Site 38
D ri v ing on Sit e 38
Ve hi cles be i ng taken int o P otline B uild i ng s 40
D ri v ing A ro u n d M o b il e P l a nt a n d E q u ipm e nt 41
W a l k i n g A r o un d t he S m e lt e r 42
P a rk i ng 43
Re v is ion 44
Se ctio n No 8 Wor kco ver A uthorit y

C ode s o f P r ac t ice 45
C e rt i fi c a t e o f C o m p e te n c y 46
Re v is ion 47
Se ctio n No 9 E quip ment Safet y Regulat io n s

E le ct r ic a l E q u ipme nt I n spe ct i o n T a gs 48
H a z a r do us S u b st ance s 48
C ut t i ng Imp le m e nts 50
Magnetic Fie l ds 51
C o n f ined S p ace s 52
Explos ive Powe re d Tools 52
G as C y linde rs 53
C om p re ssed Air 53
L if t ing E q u ip me nt 54
B arr ic ad ing 55
Re v is ion 56
Se ctio n No 10 Autho r ity t o Wo rk - Lo c ks & Tag s

A u t h o r ity t o O pe ra te 57
A u t h o r ity t o W o rk [Wo rk Pe rm it s ] 58
Lock-O ut, O ut of Se rv ice Tags, Caution Tags, Hazard Ale r t Not ice s 59
Re v is ion 67
Se ctio n No 11 T he En v ir o n me nt
E n v i r o nme nt P o l i cy 68
What If Pollut ion Occurs Where I Am Working? 69
Re d uce, Re use and Re cy c le 70
Wast e D isp os al 70
Re v is ion 71
Se ctio n No 12 Co nfi dential it y & I n fo rmatio n

P r ote c t i o n o f I n for m a t i o n 72
Me d ia Enquir ie s 72
INTRODUCTION : SAFETY AT THE SMELTER
There are strict rules about safety which everybody must obey
when entering and/or working at the Aluminium Smelter, Kurri
Kurri.
The rules are there to protect you as well as others working around you.
The smelter follows all laws relating to Occupational Health and Safety. The
requirements outlined in this booklet have been developed to help the
Smelter provide a safe working environment for everyone on site.
This book covers the general safety requirements for all persons coming
onto the Smelter site. This includes all
employees and all contractors.
The first step required is for you to read and
learn the contents of this book and then
successfully undergo a competency based
induction prior to entering and working on
the site.
All persons entering the site are also

required, by OH&S law, to take reasonable
care and comply with any requirement
imposed in the interest of the health, safety
and welfare of any persons on site (OHS Act
Section 20)
Any failure to obey and follow these

rules at all times can result in
You or others around you being

harmed or suffering injuries.
Your immediate removal from the

site.
You being fined and/or prosecuted

by WorkCover.
Disciplinary procedures being enforced.
General Site Safety Rules

Y/HSE General/Inductions Page 1
SECTION 1 : THE INDUCTION SYSTEM
The All persons requiring entry to the Smelter site

must participate in a safety induction and
General successfully undergo an assessment to
Site demonstrate understanding of the safety rules
covering the areas they need to be in and the
Safety work they are doing.
Induction
This induction covers safety requirements and rules to

enable persons to safely enter and work on the site
unaccompanied in general areas only.
Before contractors can undergo this general induction

there must be a completed site entry and induction
approval form.
This is available from:

1. The Smelter Contract Supervisor, or
2. Your Team Co-ordinator
This form requires the approval of the Smelter

Managing Director or the appointed representative.
After approval has been granted, a

suitable time and date is to be
organised for you to come to the
site and do the induction.
At the end of the induction you will be

required to do an assessment in the
form of a questionnaire. This
assessment will comprise a number of
critical questions which you must answer 100% correctly.
The balance of questions you must
get at least 80% correct.
This general site induction is valid

for 2 years.
Employees will be subject to

induction and periodic re-
assessment.

The On successful completion of the assessment

contractors will be issued a Smelter site passport
Passport book with a photo identity card.
Book
The photo identity card allows you to enter the site
whilst you are authorised to be here.
You must carry the photo identity card and passport

with you at all times whilst on the site.
Contractors - you may be required to show your

photo identity card and passport at the main gate
when you enter the plant and will have to produce
it on request whilst on the site.
Any other Smelter inductions or site training will be

entered into your passport as
and when you successfully
complete them.
The passport is your proof

that you are permitted to be
in the various areas or
conducting certain work or
operations.
The stamps in the passport will give details of any

expiry dates and when you will be required to
undergo future re-
inductions or training
sessions.
Contractors - it is your
responsibility to hand
your photo identity card
into the main gate at
the end of the job.
For employees, on successful completion of the

assessment you will be given a photo identity card
and your training records will be updated. You will
still be required to undergo future re-inductions or
training sessions.

VISITORS The inducted person is responsible for the visitor

from the time they enter the gate until they exit
the gate.
There is a Smelter Visitors Induction Brochure, which

each visitor must read, follow and sign for, each and
every time they come onto the site.
This brochure details the safety rules, dress, personal

protective equipment and how a visitor is to conduct
themselves.
The inducted person escorting the visitor is responsible

for that visitor and will ensure the visitor knows and
follows the directives in the brochure.
Visitors to site will be required to wear a high visibility

visitor vest in addition to the minimum standard PPE
as detailed in Section 4.
VISITOR

What the The General Site Safety Induction does not allow
you to enter and work in areas such as -
General
Site Safety
Induction
Does not
cover
1. Casting Plant 2. Potrooms
3. Carbon Plant 4. Switchyards
5. Confined Spaces 6. Restricted Areas
Each of these areas require separate inductions and/or

training sessions which can only be undertaken after
successful completion of this general safety induction
and if you have legitimate reasons and approval to
enter and work in these other areas.

What Work This induction does not allow you to do certain work or
jobs for which you must have specific induction,
The training or authorization.
General
Site These jobs could include such things as -
Safety
Isolation procedures
Induction
Will Not
Let You Do
Excavations
Confined spaces entry
Entry to restricted areas
Hot work
Working at heights
You must obtain information and approval, which may

require a separate induction/training, before you
undertake work or entry into other areas.
See your Team Co-ordinator or the Smelter Contract

Supervisor for more information.

R E V I S I O N
Points to Remember
The general induction only allows you to enter and work
unaccompanied in general areas at the Smelter.
You must carry your passport with you at all times.
Visitors must be accompanied at all times by an inducted person.
The general induction does not allow you to do certain work or

jobs for which you must have specific induction, training,
authorisation.
Self Test
1. Can you enter a confined space at the Smelter after you
have completed the general induction without any other
training or authorisation?
Yes No
2. Can you enter ALL work areas unaccompanied after

completion of this general site induction?
Yes No
3. Who must a visitor be accompanied by at all times whilst

on the Smelter?
_______________________________________________
_______________________________________________
_______________________________________________

SECTION 2 : PROHIBITED AND RESTRICTED
ARTICLES
What Items Due to safety issues, the following items are

banned from the smelter site.
Are
Prohibited
1 Glass bottles or jars
On Site
2 Cans
3 Cigarette lighters
4 Illicit or illegal drugs
5 Firearms and ammunition
6 Pets, animals
7 Alcohol
8 Open blade knives
If any of the above items are found on site they

must be reported to Ambulance/Security Officers at
the main gate and an incident report raised.

ARTICLES
If glass bottles and cans are inadvertently placed in scrap bins and fed
into furnaces or pots, a major explosion may occur which could result in
serious injury, damage or possibly death.
If any of the above items are found on site they must be reported to the
Ambulance/Security Officers at the main gate and an incident report
raised.

ARTICLES
What Items The following items are acceptable at the Smelter

Can You site
Bring On Examples of acceptable containers, which are classified
Site as disposable or reusable.
If a container is available at the site canteen then the

style/type has been approved and it is acceptable for
use on site.
Plastic carbonated drink bottles are permitted in

certain areas on site, and it is important that the
following rules are adhered to regarding their use:
1. Departments will manage the carbonated drink

containers within their areas;
2. The contents of plastic drink bottles can only be
consumed in non-production areas or other areas
authorized by the Department Manager;
3. The drink bottle must be completely empty prior to
disposal;
4. The empty plastic drink bottle is to be disposed of
by placing it in the blue plastic recycling bin located
in the lunch room or office area.

ARTICLES
What Items Written permission is required before the following

items will be admitted on site.
Need
Written
Permission
To Be 1 Explosives and
explosive powered tools
Allowed
2 Metal ladders and
scaffolding
3 All pressurised
containers ie paint
pressure packs, aerosol
cans, etc
4 Hazardous substances
- dangerous goods
5 Cameras
For information on how to obtain written

permission contact your -
Smelter Contract Supervisor
Team Co-ordinator
Site Safety Co-ordinator

R E V I S I O N
Points to Remember
Items that are prohibited from The Smelter include -
Glass bottles and jars Plastic bottles of similar shape to glass bottles
Cigarette lighters Alcohol
Illicit or illegal drugs Firearms and ammunition
Pets and animals
Items such as cardboard milk and juice containers are allowed

at the Smelter but must be disposed of properly in rubbish bins
provided.
You need written permission first before the following items are
allowed on site -
Explosives and explosive powered tools
Metal ladders and scaffolding
All pressurised or aerosol containers
Hazardous substances - dangerous goods
Cameras
Self Test
1. Can you bring a glass bottle of soft drink and a can of baked
beans to the Smelter for your lunch?
Yes No
2. What could happen if a glass bottle was put into a scrap bin
at the Smelter?
1 An explosion may occur
2 Nothing
3. If you need to bring an aerosol can of spray paint or similar to

the Smelter what must you obtain first?
1 A special sealed carry case

2 Written permission
3 Nothing if you do not leave it at the site

SECTION 3 : SMELTER SAFETY POLICY AND
PROCEDURES
Smelter The Smelter has an Occupational Health and

Safety policy. This policy is to ensure
Occupational
Health and Health and safety is an integral part of the
business.
Safety
All injuries and
occupational illnesses are
preventable.
Management demonstrates
leadership in safety.
Everyone is responsible for

safety.
To continuously improve
safety performance.
Copies of the policy are displayed on site. If you

would like a copy speak to your Team Co-ordinator or
Smelter Representative.
Consultation Employee involvement at all levels is critical for

ensuring a safe workplace.
Following consultation with all employees during

August 2002, OHS Committees were selected as the
primary means for consultation.
There are five OHS Committees on site; Potrooms,

Casting, Carbon, Technical Services and
Administration. All committees are made up of
employer and employee representation.
Although OHS Committees are the primary means of

consultation all personnel on site are required to
draw their supervisor's or OHS representative's
attention to any OHS concerns so the issue can be
promptly addressed. Additional methods of
consultation may be in the form of small group
discussions, toolbox sessions or team meetings.

PROCEDURES
Hyper- All contractors, their employees and sub-

contractors who have active asthma or who has
Reactive a history of recent asthma will not be cleared to
Airways or enter Hydro Aluminium Kurri Kurri.
Asthma
This is to ensure that people are not
unnecessarily exposed to production processes
which may affect this condition.
A person, who has risk factors for hyper-

reactive airways disease, will need a clearance
following a standard and appropriate respiratory
assessment.
A Respiratory Symptoms questionnaire must be

completed prior to any work at Hydro
Aluminium Kurri Kurri.
The purpose of the questionnaire is to assist

Hydro medical staff to assess whether a person
may have a respiratory condition and for
clearance to work at Hydro.
Point to Remember
Personnel who have active asthma or

have a history of recent asthma will
not be cleared to enter Hydro
Aluminium.

PROCEDURES
Who is Everyone working at the smelter is

responsible for safety at the Smelter. The
Responsible smelter must provide
For Safety 1 Safe plant
At the 2 Safe premises
Smelter 3 Safe systems of work.
You have a personal involvement in these

things.
You are responsible and

required to carry out the
following-
This means you must constantly consider

Safe
Behaviour
Observance
What could go
wrong?
What am I
about to do? What can I do to
make it safer?
You may also be asked the same

questions by others around you.

PROCEDURES
Safety Safety Sampling is one part of the safety system in

operation at our plant. All employees and contractors
Sampling are expected to be involved in the process.
Safety Sampling is a regular check

on:
The equipment we use.

The systems we work with.
The behaviours we display
at work.
People from all levels in the organisation perform these

checks, which are recorded on standard sampling
sheets. The sheets define the standards which should
be in place.
You will be involved in Safety Sampling through other

employees observing your work and by you observing
and recording what you see.
Your participation in this process will help to make our

workplace a safe place to work.
Duty The law and the Smelter requires everyone from you
to the Managing Director to exercise duty of care when
Of Care at work.
There are different levels of responsibility for duty of

care.
The Smelter, through its management, must supply

the safe place and systems of work.
You must co-operate with the

Management in implementing
and carrying out these safe
systems.
This is done by you

participating in the various
safety programs, helping to
identify hazards, following the rules and procedures
set out and promptly reporting any problems with the
systems.

PROCEDURES
The Smelter has a workplace hazard identification,

Risk risk assessment and management program as a
Management main tool for providing a safe place and safe systems
of work.
System
This is not only required by law. It is a common sense and
logical step as a pro-active approach to safety in the
workplace.
The emphasis is to identify hazards before they can harm
you and then, by a risk assessment process, either
eliminate the hazard altogether or reduce any risks to
acceptable levels.
The four elements of this program are -
1 Hazard identification
2 Risk assessment of the hazard
3 Identifying and choosing the

appropriate control for the hazard
4 Implementing the control and

ensuring ongoing effectiveness in
the workplace.
Everyone at the Smelter whether you are an employee or

contractor must participate in this program either by
participating and assisting someone else doing a risk

assessment.
OR
initiating and conducting a risk assessment yourself in

consultation with others.

PROCEDURES
Incident Everyone at the Smelter is required to promptly

report all incidents at work.
Reporting
This includes any -
Injury - no matter how small
Any incident
Any unsafe place or practice
Any near miss
By reporting near misses, unsafe places, unsafe

equipment or unsafe practices, you will be helping to
prevent future injuries occurring to yourself or others
at the site.
Report these occurrences to your
Team Co-ordinator
The Smelter Contract Supervisor
The Smelter Site Safety Co-ordinator
The Smelter has its own incident report form, which is

available from any of the above people.

PROCEDURES
Near A near miss report is our best opportunity to be proactive

and fix hazards before they reach their potential. If we
Miss act after an incident we are reactive.
Use the system, the system will highlight actions and
Hazard people responsible.
Reporting It will allocate timeframes and escalate issues not closed
out.
Note: Location of Near Miss/Hazard Report
If you have access to a computer enter report as below, if

not locate a hard copy (from supervisor or site contact) and
fill out hard copy, return to supervisor or site contact for
completion on system.
Select near miss / hazard (box up the top, near miss,

hazard),
Department and area: Dept manager will automatically
receive report,
Person reporting not compulsory, but it goes to the
selected supervisor,
Date: inserted automatically,
Risk matrix High, medium and low (as a field). Click on
likelihood and consequence to display descriptors,
The team reporting the incident,
Hazard: Drop down box,
Describe the near miss/hazard,
What actions have been taken to make it safe,
Photo click browse to find file location and upload,
Save report and review if correct,
If correct click Email it will send email and lock report.

R E V I S I O N
Points to Remember
You have a responsibility for safety whilst on the Smelter site.
You must practice safe behaviour observance whilst on the Smelter

site, where you must consider the following.
1. What am I about to do?
2. What could go wrong?
3. What can I do to make it safer?
You must co-operate with management in implementing and following

safe systems of work at the Smelter.
Everyone at the Smelter, whether you are an employee or contractor

must participate in the risk management system.
ALL incidents and near misses/hazards no matter how big or small must
be reported immediately or as soon as practically possible.
Self Test
1 List the 3 things you must constantly consider for safe behaviour
observance.
1 ________________________________________________
2 ________________________________________________
3 ________________________________________________
2 What incidents and near misses must you report immediately or

as soon as possible?

SECTION 4 : PPE, HOUSEKEEPING AND
SMOKING, DRUGS, ALCOHOL
What All persons working on the site are required

to wear the following minimum P.P.E. :
Personal
Protective
Work clothing high visibility cotton
Equipment drill shirt (190gm) with long sleeves,
PPE and cotton drill trousers, or overalls.
Must Be Fully enclosed steel cap safety

Worn at the footwear.
Kurri Kurri Australian Standards approved safety
Smelter helmet, with reflective strips.
Australian Standards approved safety

glasses.
Minimum standard PPE

must be worn on site in
all areas, unless clearly
marked as an
exception. This
includes a green zone
marked by white
painted figures on the
main entry walkways.
A solid red line
indicates that minimum
PPE is required beyond that point.
Specific P.P.E. must be worn in certain areas

of the site and when performing certain tasks
- local signs or your supervisor will indicate
specific requirements.
Individual department and specific work
inductions and training will tell you what
must be worn, where and when.

General A clean and tidy site indicates a safer site.
Housekeeping
You must play your part in keeping the site neat
and tidy with well organised work areas.
Use the bins provided.
Do not leave materials or equipment lying

around.
Clean up after yourself.

Untidy work areas and practices:
o significantly raise the risk of injury or
incident.
o are inefficient and may create fire and
other hazards.

No As part of the Smelter OH&S policy to provide a safe

and healthy environment for its employees,
Smoking contractors and visitors -
Policy
The Smelter is actively pursuing and promoting a
smoke free work place to help reduce the effects of
smoking and to protect others from passive smoking.
The rules for tobacco and smoking

at the Kurri Kurri site are:
Sale of tobacco products

prohibited on site
Smoking is banned from:-
All buildings on the site and
All buildings at other locations under the

Smelter Managements control
All vehicles and mobile equipment
All areas designated as non-smoking areas

for fire and explosive risks.
Smokers must dispose of their

cigarette butts in the receptacles
provided and not to discard them on
the ground.

Drug and All individuals entering the Smelter are required to

abide by the current Alcohol and Other Drugs Policy.
Other
Drugs Other drugs are defined as: Any
prescription, non-prescription or
Policy illicit drugs, which may create a
potential for impairment of work
performance and therefore is likely
to create a risk to an individual or
others.
Examples include, but are not limited to benzodi-

azepines, sympathomimetic amines, opiates, cannabis
and cocaine.
Under the policy

1. The sale, supply and manufacture of alcohol and
other drugs is prohibited on Hydro Aluminium
controlled sites.
2. The possession or consumption of alcohol and

other drugs is prohibited on Hydro Aluminium
controlled sites.
3. The operation of equipment, machinery and

company vehicles whilst under the influence of
alcohol and other drugs is also prohibited.
Note: Individually prescribed medication is exempt

from points (2) & (3) on the proviso that it is being
taken in accordance with directions.
The Alcohol and Other Drugs Policy may require you to

undertake testing for alcohol and other drugs on a
random, causal or post-incident basis. Refusal to
comply with the requirements of the policy will result
in disciplinary action, which may include being
removed or banned from site.
For additional information speak to your site supervisor

or contact the Employee Relations Co-ordinator.

R E V I S I O N
Points to Remember
As a minimum, all persons coming onto the site must have
and wear when necessary, or when local signs indicate -
1. Long sleeve and long trouser work clothing
2. Steel cap safety footwear
3. Safety helmet
4. Hearing protection
5. Safety glasses
You must keep the site neat and tidy, clean up after you and
put rubbish in bins provided.
The Smelter has a no smoking policy which must be followed at

all times.
No alcohol or non-prescribed drugs are allowed on the site.
Self Test
1 List the 5 items of dress/PPE you must have and wear when
necessary.
1 ________________________________________________
2 ________________________________________________
3 ________________________________________________
4 ________________________________________________
5 ________________________________________________
2 What buildings are you allowed to smoke in?
___________________________________________________
3 Can you bring alcohol or non-prescribed drugs onto the site?
Yes No

SECTION 5 : EMERGENCIES, FIRST AID - PEO
There are emergency procedures and equipment on the

Smelter site that are designed to save lives. These include
the
Emergency Response Plan

Fire Suppression Systems
Portable Fire Extinguishers
First Aid Equipment
Plant Emergency Organisation (PEO).
They ensure that the plant and people are covered for any
emergency 24 hours of every day in the year.

The Plant The PEO exist at the Smelter site to provide the
first response to any threatening incident,
Emergency accident or major disaster.
Organisation
(PEO) The PEO crew is distinguishable by
the Red safety helmets.
You can contact the PEO by either
Phoning on the EMERGENCY number -

2 0 0 or
Using a two way radio or
Operate the nearest break glass

station.
The PEO has access to an onsite Fire Engine, an

Emergency Rescue 4WD vehicle and the onsite
Ambulance. If any of the PEO vehicles sound their
sirens, please move out of their path immediately.

How to When there is an emergency in your i m m e d i a t e

work area you can contact the Ambulance/Security
Raise an Officer at the main gatehouse by either
Alarm
Calling 200 on any site
phone or mobile 49370200
or;
Calling on any two way radio

using Channel 3 or;
Operate a break glass

station.
In the event that an emergency or major incident

occurs it is important that everyone stays calm.
Make sure that you, your work mates and anyone
else nearby are not in any further danger.
When reporting an emergency clearly communicate:-
1. The location.
2. Nature of the emergency.
3. Number of people affected.
4. Types of injuries.

What You There are two plant alarms to advise you of any
emergency.
Do If You
Hear An If the EMERGENCY is in the department you are
in, the SIREN will sound ON-OFF-ON-OFF.
Alarm
There are three things that you must do if the

emergency is in your department.
1. Look for
danger to
yourself.
2. If there is
immediate
danger,
evacuate to
the assembly
area.
3. If there is no immediate danger, wait for

instructions from either the PEO, your
Emergency Warden or Team Co-ordinator
or Smelter Contract Supervisor.
If the EMERGENCY is outside the department you

are in, the SIREN or bell will sound
CONTINUOUSLY.
There are two things that you must do if the

emergency is outside your department.
1. Still look for danger to yourself.
2. Stay at your work area unless the PEO,
Emergency Warden or your Team
Co-ordinator/Smelter Contract Supervisor
advises you otherwise.

Fires The lighting of any fires on the Smelter site is strictly

prohibited unless written permission has been
obtained from the PEO Leader and adequate
safeguards have been put in place.
If a fire starts in the area you are working in you

should do the following things;
Raise the alarm, either

o Dial 200 to advise the location of
the fire
o Call the Main Gatehouse on a two-
way radio(Channel 3)
o Operate a Break Glass Station.
Let people in the area know about the fire.
When the PEO arrives, let them take over, as

this is what they are trained for.
Depending on the size

and location of the fire
you can elect to use an
extinguisher to suppress
the fire.
However remember :-
1. This is generally limited to small localised fires.

2. Do not put yourself in immediate life
threatening situations.
3. This is a judgement call and would
depend on the circumstances at the
time.

Fire There are a number of fire extinguishers

located throughout the Smelter site for various
Extinguishers types of fires.
Fire hydrants and hose reels are also located

on various parts of the plant and must not be
used for any purpose other than fighting fires.

What are The order to evacuate all or part of the plant

will be given by the PEO Leader.
The
Evacuation
Procedures If an evacuation has been ordered, you must
For the follow these rules :-
Smelter
1. The evacuation of each section is under
the control of the Emergency Warden for
that section.
Listen carefully to the instructions given

by the Emergency Warden. When directed
to evacuate, go to the nominated
Assembly Area and wait for their
instruction.
2. Remain calm at all times.
DO NOT RUN.
WALK BRISKLY
3. Do not return to your department or work

area until you have been advised that you
can by the Emergency Warden or the PEO
SHOULD A MAJOR INCIDENT OCCUR, THE SITE

AMBULANCE AND PLANT EMERGENCY CREW IS
CALLED BY RINGING 200 ON ANY TELEPHONE
EXTENSION.
This phone number is written on every phone at

the Smelter.

First Aid If you are injured at work, no matter how small the
injury, you are required to report it to your Team
Facilities Co-ordinator or Smelter Contract Supervisor and
report immediately to the Medical Centre so you
can receive appropriate treatment.
The Medical Centre is located at the Main

Gatehouse and is open 24 hours/day, 7 days/week.
You can contact the Medical Centre during daywork

on ext. 511 and after hours on ext. 263.
Injury If you are injured while working on site, the

Smelter has programs in place to manage your
Management injury and provide rehabilitation (treatment,
And physiotherapy, modified work duties etc).
Rehabilitation The objective of the programs is to help you

recover and return to full pre-injury status as soon
as possible.
The Smelter Worker's Compensation Co-ordinator

can be contacted via the Medical Centre (extension
511).
Rehabilitation and Workers Compensation for

contractors who suffer injuries while working on
site are managed by the company they are
employed by.

R E V I S I O N
Points to Remember
The Emergency Phone No. on site is 200.
The Plant Emergency Organisation (PEO) provides first response to any threatening
incident, accident or major disaster at the Smelter.
To raise the alarm you can either
1. Use the phone 2. Call on a two way radio Channel 3 3. Operate a break
glass station
If you hear an alarm in the department or area you are in, you must -
1.Look for danger to yourself.
2. If there is immediate danger, evacuate to the assembly area.
3. If there is no immediate danger, wait and follow any instructions from the
PEO, Emergency Warden or Team Co-ordinator/Smelter Contract Supervisor.
You cannot light any fire on the Smelter without written permission from the PEO Leader.
You can elect to use the appropriate fire extinguisher to contain small localised fires but
do not put yourself in any life threatening situation.
The PEO Leader is responsible to order the evacuation of all or part of the Plant.
You must follow the instructions of the Emergency Warden for each section and not
return to your department or work area until advised that you can by the Emergency
Warden or the PEO.
There is a medical centre located at the main gatehouse open 24 hours a day 7 days a week.
Self Test
1 What is the on site emergency phone number? _____________________
2 Who is responsible to provide first response in any emergency at the Smelter?
_______________________________________________________________
3 What are the 3 ways of raising an alarm at the Smelter?
1 ____________________________________________________________
2 ____________________________________________________________
3 ____________________________________________________________
4 What are the 3 things you must do if there is an alarm in your department or work
area?
1 ____________________________________________________________
2 ____________________________________________________________
3 ____________________________________________________________
5 Who must you get written permission from to light a fire on the site?
_______________________________________________________________
6 What 3 rules must you follow if an evacuation has been ordered?
1 __________________________________________________________
2 __________________________________________________________
3 __________________________________________________________

SECTION 6 : SIGNS
You must look for hazards because they are all around
you. Look for signs, flags and barricades etc that warn
you about hazards. Some of the Safety signs you will
see at the Smelter site look like these.
RED The RED safety signs show what you

SAFETY must NOT DO in that area.
SIGNS
BLUE The BLUE safety signs tell you what

SAFETY kind of safety clothes and equipment
SIGNS is MANDATORY when entering a
particular area.

SECTION 6 : SIGNS
YELLOW The YELLOW safety signs show
SAFETY that there can be a danger or a
SIGNS risk to your health and you must
proceed with caution in or
around these items.
GREEN The GREEN safety signs show

SAFETY you exits, safe assembly areas,
SIGNS first aid etc.
Where there is work in progress, the appropriate
warning signs, flashing lights and portable barricades
must be displayed. If you need advice on what is
required at your work site, contact your Team Co-
ordinator or Smelter Contract Supervisor.
Barricades are used to stop unauthorised entry into a

dangerous area, and may be used on either warning
or protective barriers.
Unauthorised entry into barricaded areas is not

permitted. Permission must be obtained from the
person in charge prior to entering the barricaded
area.

R E V I S I O N
Points to Remember
Constantly look for hazards which may affect you.
Follow the directions displayed on all signs you see at the Smelter
Where appropriate, warning signs, flashing lights, portable

barricades must be displayed in addition to any fixed signs,
barricades present at the Smelter.
Self Test
1 What do RED signs mean?
____________________________________________________________________
2 What do BLUE signs mean?
____________________________________________________________________
3 What do YELLOW signs mean?
______________________________________________
4 What do GREEN signs mean?
______________________________________________

SECTION 7 : SAFETY FOR VEHICLES, DRIVERS
AND PEDESTRIANS
Vehicles You are only allowed to drive on the Smelter site for
work reasons.
On Site
Permission from the Ambulance/Security Officer is
required for access for your vehicles.
Your vehicle is subject to inspection by the

Ambulance/Security Officer.
The musts for driving vehicles on the site

Driving are: -
On Site
The maximum speed limit on roads on the Kurri Kurri
Smelter site is 12kph unless otherwise signposted.
You must also consider other conditions when you

drive on the site, such as local work hazards, weather,
mobile plant etc.
As a driver, you must be appropriately licensed (An

RTA learners permit is not acceptable).
You and your passengers must wear seat belts (where

fitted).
You must follow all road signs.

AND PEDESTRIANS
Driving You must wear safety glasses in your vehicles if the

windows are wound down.
On Site
You are not allowed to transport people or be

transported yourself in the back of a truck or utility.
Your vehicle is not permitted

within any building without
permission of the Team Co-
ordinator in that area.
When driving your vehicle you must avoid Hot Metal

areas and give way to Molten Metal vehicles.
Any load on your vehicle must be safely secured

and loose loads must be secured when leaving the
site.
Children and pets are not

allowed to enter the Smelter site.

AND PEDESTRIANS
Vehicles In the Potline Buildings it is possible to short circuit

between a pot on one side of the building and a pot on
Being the other side. If this happens, massive electrical
Taken arcing occurs that could have catastrophic
consequences including injury and damage.
Into
Potline High-risk vehicles are insulated to assist in reducing
the risk of short-circuit. But it is possible that other
Buildings non-insulated vehicles may need to be used in a
Potline. The following rules apply:
The driver must be Potroom inducted or under the

control of a Potroom inducted person.
Correct procedure must be used, or a
Risk assessment must be undertaken before the
vehicle can be used in a Potline building.
All non-Potroom vehicles carry the sign shown below

as a reminder:

AND PEDESTRIANS
Driving There are three things for you to remember when

driving around the site and you encounter mobile
Around plant.
Mobile
Plant and STAY ALERT
Equipment
STAY AWAY
BE PATIENT

AND PEDESTRIANS
Walking When walking around the Smelter site always walk on

the footpaths or walkways which are marked. Do not
Around take short cuts. Running on the plant is strictly
The forbidden as well. Pedestrians must give way to
vehicular traffic at all times and use marked crossings
Smelter where provided when crossing the road.
Always stay well clear of all mobile equipment like

anode haulers, hot metal transport vehicles, forklifts
etc. Often the driver does not have a clear view and
may be unable to stop quickly in an emergency
situation.
When you have to approach moving mobile

equipment
Attract the attention of the driver

Approach when you have been seen
Do not approach from a blind spot

AND PEDESTRIANS
Parking Before you leave your vehicle check that you
Parked in a place marked as a carpark
Are not restricting traffic
Are not behind or too close to mobile plan

R E V I S I O N
Points to Remember
You must have permission from the Smelter site security before you can bring
your vehicle onto the site.
Your vehicle is subject to inspection by the Smelter Ambulance/Security
Officer.
The maximum speed limit on roads at the Smelter is 12 KPH.
Drivers and passengers must wear seat belts when fitted.
You must follow and obey all road signs.
You cannot drive a vehicle into any building without permission from the Team
Co-ordinator in that area.
Children and pets are not allowed to enter the Smelter.
You must be very careful when you encounter any mobile plant when driving around
the site, by -
1. staying alert
2. staying away from the mobile plant
3. being patient
Pedestrians must give way to vehicular traffic at all times and use marked
crossings where provided when crossing the road
You must not run on the site and always walk on the footpaths or walkways.
You can only park in areas marked as a car park and do not restrict other
vehicles or mobile plant.
Self Test
1 Do you need permission to drive your vehicle on the Smelter site?
Yes No
2 What is the maximum speed limit on the Smelter roads?
_______________________________________________________________________________
3 You must wear safety glasses in a vehicle if the windows are
wound down -
Yes No
4 What must you do if you need to drive into a building on the
Smelter?
_________________________________________________________________________________
5 Where can I park on the Smelter site?
________________________________________________________________________________
6 Vehicles have the right of way over pedestrians at all times?

Yes No

SECTION 8 : WORKCOVER AUTHORITY
Codes At the Smelter site rules and procedures exist, which

are in place for the safety of you and your workmates
Of Practice and to ensure we produce aluminium efficiently.
In addition the WorkCover Authority has rules for

working safely.
They apply to all worksites and there are some rules

specific to the Smelter site. These rules cover such
things as safe lifting methods, the correct use of
harnesses and safety belts and working at heights.

SECTION 8 : WORKCOVER AUTHORITY
Codes The WorkCover Authority rules state that you must

have a Certificate of Competency to do some jobs, for
Of Practice example:
Scaffolders, Crane Drivers, Plant Operators, Riggers,

Crane Chasers/Dogging, Explosive Power Tools.
MUST
BE ON
SITE
You must have your Certificates of Competency on you

(your person or locker/bag) at all times when on the
Smelter site.
If you dont follow the rules set

out by the Smelter or WorkCover
you can be personally liable to a
fine, court action or gaol.

R E V I S I O N
Points to Remember
In addition to the Smelter site specific safety rules and procedures - you
must also follow all WorkCover Authority rules whilst on site.
WorkCover require you to have a current certificate of competency to do
some jobs or operate certain equipment. You must have the appropriate
certificate available on the Smelter site.
Self Test
1 Where must your current WorkCover certificate be when doing
jobs or operating equipment requiring such certificates?
__________________________________________________
2 What could you be liable for if you dont follow the safety rules set
out by the Smelter or WorkCover?
__________________________________________________
__________________________________________________
__________________________________________________

SECTION 9 : EQUIPMENT SAFETY
REGULATIONS
Electrical When your work does not require you to approach or

handle electrical equipment or cables, keep away from
Equipment them. At all times, electrical equipment must be
Inspection thought to be live and dangerous. Treat it with respect.
Tags All electrical tools, appliances, leads etc. must be

inspected by a licensed electrician and have a
current inspection tag attached to the equipment
before you can use the equipment at the Smelter.
No tag....No use.
Hazardous Working with or coming into contact with hazardous

substances can be extremely dangerous to your health
Substances and well being.
Hazardous substances can have an immediate effect

on you or in some cases have a long term effect which
is not immediately felt.

REGULATIONS
No hazardous substance can be brought into the

Smelter without -
1 A current (within the last 5 years) Material Safety

Data Sheet (M.S.D.S.)
2 The container being correctly labelled and

readable.
3 A risk assessment for the specific use for which

the hazardous substance is intended to be used.
4 Written authorisation from the Smelter's Site

Safety Co-ordinator.
The correct control measures, as

required by the risk assessment,
must be observed at all times when
handling, storing and using
hazardous substances.
If decanting of hazardous substance

from one container to another is required, you must
ensure
that the container the hazardous substance is being

transferred into is made of material which will
safely hold the substance.
that the container the hazardous substance is being

transferred into is correctly labeled

REGULATIONS
No residues or partially used containers of hazardous

substances are to be left around the Smelter. Left
over hazardous substances must be either
removed from the site or
disposed of correctly or
stored on the site correctly
Cutting A spring loaded (self retracting) metal safety knife is

the approved style for the Hydro site and is only to be
Implements used where there are no other alternatives. Persons
who have identified they need to use a knife for
activities on site, are required to complete a risk
assessment and also seek approval from the relevant
Hydro supervisor.

REGULATIONS
Magnetic The potlines (and other areas on site) emit strong

magnetic fields that may have an effect on people who
Fields have medical implants and/or heart pacemakers, as
well as possible effects to unborn children of females
during pregnancy.
You must inform your Site Supervisor if you are likely

to be affected by strong magnetic fields so necessary
precautions can be taken.
Magnetic fields in the potlines may affect:
Analogue Watches
Heart Pacemakers or
other implanted
electronic devices
EFTPOS and Bankcards, Credit

Cards etc
These items should not be taken

into the Potline area.

REGULATIONS
Confined There are a number of areas or jobs which are defined

as work in a confined space.
Spaces
Specific safety and training requirements apply to
these areas and are outlined in the Confined Spaces
Manual.
You will need to attend specific

training if you are required to
enter or work in, on or around
confined spaces
Explosive If you are going to operate explosive powered tools on

the Smelter site you must obtain an authorised work
Power permit and written permission from the Site Safety
Tools Team first. They can be contacted on extension 652
or 235.

REGULATIONS
Gas When you are working with or around gas cylinders,

you need to take special precautions.
Cylinders
Gas cylinders are not to be left free standing
Secured so they cannot be
accidentally knocked over
Only lift one cylinder at a time
Do not store cylinders in hot places or where sparks
can reach them
Oils and greases must not come
into contact with compressed
oxygen cylinders.
When entering the plant with gas cylinders, you need

a tag from the Ambulance/Security Officer for each
cylinder you bring onto the plant. When you leave
the plant with your cylinders, the tags are returned to
the Ambulance/Security Officer.
All your gas cylinders must have current pressure test

stamping as required by the WorkCover Authority and
Australian Standards
Welding To reduce the risk of electric shocks from welding
voltages all welders used on site shall be fitted with
Equipment either:
VRD (voltage reducing device), complying with

AS1674
Trigger switch that opens the welding circuit unless

it is closed, complying with AS1674 (typically MIG
welders)
Compressed Compressed air is used on the site for specific
purposes but it can be a dangerous tool and you need
Air to be careful using it in the workplace.
Do not use compressed air to remove dust from

clothing
Do not direct a stream of compressed air at yourself or

your workmates.

REGULATIONS
Use of The minimum requirements for the safe use of lifting

equipment at the Smelter is to ensure the safety of all
Lifting personnel and equipment on site.
Equipment
Therefore, Contractors and their Sub-Contractors
shall:
1. Comply with the relevant Australian Standards and

Smelter requirements for the safe use of lifting
equipment.
2. Use suitably qualified personnel.
All lifting equipment to be utilised at the Smelter must

have a current inspection tag attached.
The Contractor shall be required to keep and maintain a

Site Register of all lifting equipment to be used on site,
including but not limited to, web slings, chain slings,
shackles, chain blocks, mobile cranes and hiabs.
The Site Register shall include the following information:
Description of each item

Safe Working Load Limit of each item
Inspection date of each item
WorkCover Tickets for users of the equipment
Crane Safe Certificates

REGULATIONS
Use of Barricades are to be used at the Smelter for the

control of hazardous situations that may occur
Barricading through planned or unplanned events.
Types of Examples of
Barricading Practical Application
Working at heights (fall/drop zone),
Temporary Fencing excavations, restricted areas, longer term
Physical maintenance / construction activities.
Barricading Protect people and work areas from vehicle
Concrete Barriers traffic, excavations, longer term maintenance
(Most Effective) construction activities and mobile equipment.
Protect people and work areas from vehicle
Water Filled Barriers
traffic and mobile equipment.
A-Frame Barricading excavations, restricted areas, longer term
maintenance activities.
Visual Barriers Working at heights (fall/drop zone),
High Visibility Cones,
excavations, restricted areas, longer term
Chains & Mesh
(Least Effective) maintenance activities.
Red & White Barrier
excavations, restricted areas, longer-term
tape
maintenance activities, crane lifts, temporary
REQUIREMENTS FOR ENTERING BARRICADED

AREAS
Entry to a barricaded area is restricted to authorised

personnel only. Other personnel MUST obtain
permission from the person in charge prior to entering
the barricaded area and have an understanding of the
hazards and potential risks.
To enter a barricaded area a person must:

1. Be following a written CBP/ JSA/ SOP or Risk
Assessment; or
2. Have been authorised by the person

responsible for managing the barricaded work area
(this also applies when there are no written Current
Best Practice).

R E V I S I O N
Points to Remember
All electrical tools and leads must have current inspection tags attached.
You cannot bring a hazardous substance into the Smelter without -
1. A current MSDS.
2. Correct and readable labelling.
3. A risk assessment covering the hazardous substance and the specific
task for which it is intended to be used.
4. Written approval from the Smelters Site Safety Co-ordinator.
There are strong magnetic fields in the Potline areas which may affect -
1. analogue watches
2. heart pacemakers or other implanted electrical devices
3.eftpos, bankcards, credit cards etc.
You cannot enter a confined space at the Smelter without specific training and
authorisation.
You must have an authorised work permit and written permission from the Site
Safety Team before you can bring or operate explosive powered tools on the
Smelter site.
Gas cylinders must be secured, handled safely and have a tag from the
Ambulance/Security Officer whilst on the Smelter site.
All lifting equipment to be utilised at the Smelter must have a current inspection
tag attached and comply with the relevant Australian Standards.
Entry to barricaded area is restricted to authorised personnel only.
Self Test
1 Do you need written permission to bring a hazardous substance on site?
Yes No
2 What are 3 things the magnetic fields in the Potline area may affect?
1 __________________________________________________________
2 __________________________________________________________
3 __________________________________________________________
3 What is the basic rule for electrical tools or leads.

NO TAG - NO ................................................................
4 What do you need to attend before you can enter a confined space at the Smelter site?
______________________________________________________________
5 All gas cylinders you bring on site must have tags from Ambulance/Security Officer -
Yes No
6 What is the requirement for the safe use of lifting equipment at the Smelter?
_______________________________________________________________
7 What are the requirements a person must have to enter a barricaded area?
1 _________________________________________________________
2____________________________________________________________

SECTION 10 : AUTHORITY TO WORK
LOCKS & TAGS
Authority There are many types of equipment and processes at

the Smelter site that we consider hazardous enough
To for you to have a permit, certificate or licence to
Operate operate them. We call this Authority to Operate.
It ensures that when you are working in potentially

hazardous activities you comply with the standards
that are outlined in either the training or written
procedures.
At the Smelter site there is a range of regulated and

non-regulated plant and equipment that require you to
be trained and to demonstrate competency (written or
oral) in using.
Regulated The regulated plant includes (but is not limited to):
Plant Forklifts
Bridge and Gantry Cranes
Slewing and Non-Slewing Mobile Cranes
Skid Steer Loaders
Wheelbreakers
Front End Loaders
Excavators
Elevating Work Platforms (Boom type) with a reach
>11 metres
Scaffolding
These require pre-operational

inspections every time you use
them

LOCKS & TAGS
Authority The non-regulated plant includes (but not limited to):
To
Operate
Battery Cars
Pendant Control Cranes
Maintenance Utes and Service Vehicles
Anode Haulers
Tractors
Metal Haulers
Ore Trucks
Sweepers
Elevating Work Platforms (Boom type) boom
length <11 metres
Scissor Lifts
Your competency in operating this plant and

Non equipment will be reassessed at regular intervals.
Regulated
Plant
If your reassessment identifies a need for refresher
training, your Team Co-ordinator will organise this for
you. Contractors are required to organise and provide
their own training and refresher training.
These require pre-operational

inspections at least once a
shift

LOCKS & TAGS
Authority There are some tasks at the Smelter site that we have
identified as high risk. To have the authority to work
To on these tasks you will need additional training and
Work verification. Also a work permit will be required.
Work permits can be arranged through your Team Co-

Work ordinator or the Smelter Contract Supervisor.
Permits These high-risk tasks include (but are not limited to):
Work Permit with 'General Control Measures'

Form
Smelter Employees working in departments

other than their normal work place.
Contractor work.
Specified Restricted Areas (identified by signage
at the area).
Scaffolding.
Complex/Multiple source isolations.
Live electrical work.
Liquid Pitch/Heating Oil/Chlorine systems.
Work at heights (outside platforms or railed
areas - above 1.8m).
Work Permit with 'Special Control Measures'
Confined Space Entry.

High Voltage Work.
Specified Hot Work.
Excavation, Pile Driving.
Work using Explosive Powered Tools.
You must comply with the written procedures for these

high-risk tasks.
If a written procedure does not exist, you need to

complete a risk assessment to identify the hazards,
assess their risk and apply controls before you
commence work.

LOCKS & TAGS
Isolation At the Smelter site there are five [5] tags that we
use.
Identification
Tags,
Out of Service Tag Caution Tag
Visitors
Personal
Lock
Identification
Tags,
Out of
Service Tags,
Caution Tags Isolation

& Hazard Identification Tag Hazard Alert Notice
Alert Notices
Visitor Personal Lock

Identification Tag

LOCKS & TAGS
Isolation - The lockout tagout system is used for your personal

protection.
Lockout
Tagout Personal Lock - Red Lock
The only lock that provides personal protection.
The red lock must identify the owner's name and
workgroup.
Equipment Lock Yellow Lock

1. The yellow equipment lock is used for the sole
purpose to demonstrate the isolation has been
verified.
2. The yellow lock is not for personal protection.
3. Protected Persons never use these locks.
4. A purple and white striped tag is attached to these
locks to identify the isolation controller or the group
isolation board.
Group Lock Green Lock

1. Is used to lock a Group Isolation Board that hold
the key(s) of all the yellow equipment locks and the
isolation checklist after the isolations have been
verified.
2. Not for personal protection, Protected Persons
never use these locks.
Project Lock Blue Lock

1. Is used solely for the purpose of project isolations
when isolations must be under the control of a
manager.
2. This lock is to remain in place until testing
commissioning is to take place.
Multilock Device
A device that allows more than one lock to be attached
to an isolator.
Remember the LOCK is the KEY to

your SAFETY

LOCKS & TAGS
Protected Prior to undertaking any isolation on site you must be

trained to be a Protected Person. This training will be
Person conducted or organised by your Team Co-
ordinator/Contract Supervisor.
1. A Protected Person is any person who is to be

protected by an isolation.
2. They must fit their own red personal locks and have
this witnessed.
3. Red locks are used for the sole purpose of

protecting their owner. They are the only locks that
provide personal protection.
4. Red locks are identified by the owner's name and

workgroup or their contracting firm.
5. Visitors personal lock identification tags are used to

identify red personal locks that are not identified with
the users' name. This tag is utilised by visitors,
contractors or Hydro employees who use locks on an
infrequent basis. This tag alone does not provide
protection.
6. You, the owner of the red lock, control the key.
7. If you lose your key contact your Team Co-

ordinator/Contract Supervisor.
8. Remember the red lock is your lock, your key, your

protection and your responsibility.
Isolation There are 2 isolation types used at the Kurri Kurri

Smelter:
Types
1. Simple isolation 3 or less isolation points to be
secured
2. Group isolation mandatory if 4 or more isolation

points are to be secured

LOCKS & TAGS
Isolation There are two types of isolation tags used at the

Smelter.
Tags
Isolation Identification Tag

A purple and white tag that identifies the person who
carried out the isolation and verification. It also
identifies where the key to the yellow equipment lock
is.
Visitors Personal Identification Lock Tag

This tag is used to identify red personal locks that are
not permanently identified with the owners name.

LOCKS & TAGS
Out OUT OF SERVICE TAGS are used to prevent the use of

unsafe plant, equipment and machinery.
Of
Service 1. If you can see that the use of unsafe plant,
equipment and machinery could cause further
Tags damage or injure someone you must place an
Out of Service Tag on it.
2. You must write on the Out of Service Tag the

date, your name, your department and any
explanatory information about why caution is
needed.
3. It is the responsibility of each individual to place

an Out of Service Tag on the isolating switch,
valve, etc. without delegation.
4. The Out of Service Tag shall be securely fixed so

that it will not become detached.
5. You must let your Team Co-ordinator or the

Smelter Contract Supervisor know as soon as
possible or before you leave the Smelter site,
that an Out of Service Tag has been placed on
plant, equipment or machinery.
6. An Out of Service Tag can only be removed

once the plant, equipment or machinery is in
proper working order. To do this you need
authorisation by your Team Co-ordinator or
authorised representative.
7. You must remember that an Out of

Service Tag does not provide you
with personal protection, because it
can be removed without you being
aware of it.

LOCKS & TAGS
Caution CAUTION TAGS are used to warn you that people are
testing equipment which is still energised and not
Tags under the control of a Red Lock
1. A Caution Tag is NOT a substitute

for a Red Lock. When power is isolated,
you must use a Red Lock.
2. You must write on the Caution Tag the date,

your name, your department. Further
explanatory information can be provided on the
tag.
3. People carrying out live testing have the

responsibility to place a Caution Tag on the
isolating switch, valve, etc. without delegation.
4. The Caution Tag shall be securely fixed so that

it will not become detached.
5. You must remove your own

Caution Tag. Do not remove anyone elses
Caution Tag.

LOCKS & TAGS
Hazard HAZARD ALERT NOTICES are used to warn you of

potentially hazardous situations which can occur
Alert suddenly and are unusual and are not commonly
Notice encountered.
The purpose of the hazard alert notice is to:
Provide a quick and efficient method for

alerting people to a new hazard present in
their work area.
Encourage reporting and ensure that

immediate steps are taken to control the
hazard.
Ensure the Team Co-ordinator responsible

for the area is aware that the hazard exists.
Steps when using the hazard alert notice.
1 You - complete a hazard alert notice and post it

in a prominent position near the hazard.
2 You - take some immediate steps to control the

hazard
3 You - provide a copy of the notice to your

Team Co-ordinator or the next available Team Co-
ordinator
4 You - initiate an incident investigation report.

R E V I S I O N
Points to Remember
There are many types of equipment and processes at the Smelter site
that you will require an authority to operate permit before you proceed.
Some high risk tasks have been identified at the Smelter site which
require additional training and a work permit.
There are 5 types of tags used at the Smelter site.

1. Isolation Identification tags
2. Visitors Personal Identification tags
3. Out of Service tags
4. Caution tags
5. Hazard Alert tags
The red locks are used for your personal protection and require 4 basic
rules.
1. YOU - FIT YOUR OWN LOCK
2. YOU - HAVE IT WITNESSED
3. YOU - CONTROL YOUR OWN KEY
4. YOU - REMOVE YOUR OWN LOCK
Self Test
1 What are Red Locks used for?
______________________________________________
2 What are Out of Service tags used for?
______________________________________________
3 What are Caution tags used for?
______________________________________________
4 What are Hazard Alert tags used for?
______________________________________________
5 What are the 4 basic rules for Red Locks?
1 _____________________________________________
2 _____________________________________________
3 _____________________________________________
4 _____________________________________________

SECTION 11 : THE ENVIRONMENT
Environment The protection of the environment at the Smelter site

is treated very seriously. It is policy that every person
Policy working at the Smelter is responsible for the
environment.
We operate under an Environmental Licence, which

has standards that must be followed. Failure to
follow the licence conditions can not only result in
severe penalties, but has an impact on the quality of
lifestyle for you, your family and those in the local
community.
When doing your work at the Smelter site you must

consider the impact the job will have on the
environment.
You must then put in place controls to protect the

environment.
You must follow standards to protect the

environment. These include but are not limited to:

What You MUST

If
Pollution Take safe steps to stop it straight away;
Occurs
Where
I am
Working
Reduce its effect as much as practical;
Report the pollution to your Team Co-ordinator or the

Smelter Contract Supervisor.
You must report all liquid or solid spills to the

Ambulance/Security Officer, if you cannot remove
them easily and safely.

Reduce At the Smelter site it is our policy to:
Reuse
And
Reduce the amount of waste we produce.
Recycle
Reuse the material where we can.
Recycle the material and use it for something

else.
Waste Any Waste Disposal shall be to appropriate

environmental standards.
Disposal
For more information contact your Team Co-ordinator
or the Smelter Contract Supervisor.

R E V I S I O N
Points to Remember
Failure to follow the rules for the Smelter environmental licence can not
only result in severe penalties, but has an impact on the quality of lifestyle
for you, your family and those in the local community.
If pollution occurs where you are working you must follow these basic
rules -
1. Take safe steps to stop it.
2. Reduce its effects.
3. Report the incident.
At the Smelter you must as far as practical -

1. Reduce amount of waste you produce.
2. Re-use materials where you can.
3. Recycle materials.
All waste disposal will be to appropriate environmental standards.
Self Test
1 What are the 3 basic steps to follow if pollution occurs in your
work area?
1 _________________________________________________
2 _________________________________________________
3 __________________________________________________
2 You can flush liquid waste material down sinks and drains.
Yes No

SECTION 12 : CONFIDENTIALITY &
INFORMATION
Protection All due care must be taken by employees to

protect the companys interests and intellectual
Of property.
Information
Information which is commercial-in-confidence
and or confidential in nature to Hydro or other
parties must not be released without the site
Managing Directors permission.
Media Media enquiries or external requests for

information are to be referred to the Managing
Enquiries Director.
Under no circumstances is anyone to deal

directly with the media without prior
authorization.

ABN 55 093 266 221
PO Box 1
Kurri Kurri NSW 2327
Australia
Phone: (612) 4937 1555

Fax: (612) 4937 3452

Appendix B
Respiratory Symptoms Questionnaire Contractors Hydro No.
Name: Contracting Company:
Please tick the boxes Yes or No

Yes No
1 Are you troubled by long-lasting coughing?
Do you ever experience shortness of breath or difficulty in
2
breathing?
3 Does your chest ever sound wheezing or whistling?
4 Have you been diagnosed with Asthma?
5 Do you take Asthma medication (e.g. puffers or tablets)?
Have you previously had Asthma (e.g. as a child after 10 years of
6
age)?
7 Have you previously taken Asthma medication?
Statutory Declaration
I .(full name), currently employed

by , solemnly and sincerely
declare that my answers to these questions are truthful and accurate to
the best of my knowledge.
I make this solemn declaration by virtue of the Statutory Declarations Act

1959 and subject to the penalties provided by that Act for the making of
false statements in statutory declarations, conscientiously believing the
statements contained in this declaration to be true in every particular
aspect.
Declared at ....
In the State of ....
This .. Day of .. 20 .
Signature of Declarant .. DOB .
Signature of JP . JP No. ..
Name of Witness .
Address of Witness .
Authority/Consent
I (full name) consent to Hydro Aluminium Kurri Kurri:

(a) providing my employer with this assessment;
(b) providing my employer with information regarding the outcome of this
assessment;
(c) forwarding this assessment to a physician employed by Hydro Aluminium Kurri
Kurri or a Respiratory Physician nominated by myself or my employer; and
(d) retaining a copy of this assessment for file for up to five years.
Signature .. Date .


General Site Safety Rules Rev 21

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General Site

Welcome to the Hydro Aluminium Kurri Kurri General Site Safety

Q: How do I "pass" the induction?

Q: What do I need to bring with me to the induction?

Q: What will happen if I do not "pass" the induction?

Q: What do I need to bring with me to the retest?

Q: What if I don't "pass" the retest?

ID NO: ________ CARD NO: ________ PASSPORT NO: __________

Office Use Only

Applicant is: Competent Knowledge

Not Yet Competent

Comments/Feedback (Assessors to make any additional comments which

Date of Assessment: _____________________________

C.2. C.7. C.12. 17. 22.

C.3. C.8. C.13. C.18. C.23.

4. C.9. C.14. C.19. C.24.

C.5. 10. C.15. C.20. 25.

APPLICANT'S SIGNATURE: DATE:

ASSESSOR'S SIGNATURE: DATE:

1. Review and understand the contents of this booklet before you

2. If you are a contractor, complete the Contractor Site Induction detail

Remember all the requirements

Se ctio n No 1 T he Induct ion S yst em

Se ctio n No 2 Pro hi bited & Re stri ct ed Arti cle s

Se ctio n No 3 S melt er Safet y Po li cy & Proc eed ing s

Se ctio n No 4 PPE - Housekeep ing & S mo king, Drug s,

Se ctio n No 5 E merg enc ies, First Aid - PEO

Se ctio n No 7 Sa fet y Fo r V ehicle Dri ve rs & Pede strians

Se ctio n No 8 Wor kco ver A uthorit y

Se ctio n No 9 E quip ment Safet y Regulat io n s

Se ctio n No 10 Autho r ity t o Wo rk - Lo c ks & Tag s

Se ctio n No 12 Co nfi dential it y & I n fo rmatio n

All persons entering the site are also

Any failure to obey and follow these

You or others around you being

Your immediate removal from the

You being fined and/or prosecuted

Disciplinary procedures being enforced.

General Site Safety Rules

The All persons requiring entry to the Smelter site

This induction covers safety requirements and rules to

Before contractors can undergo this general induction

This is available from:

This form requires the approval of the Smelter

After approval has been granted, a

At the end of the induction you will be

This general site induction is valid

Employees will be subject to

General Site Safety Rules

The On successful completion of the assessment

You must carry the photo identity card and passport

Contractors - you may be required to show your

Any other Smelter inductions or site training will be

The passport is your proof

The stamps in the passport will give details of any

For employees, on successful completion of the

General Site Safety Rules

VISITORS The inducted person is responsible for the visitor

There is a Smelter Visitors Induction Brochure, which

This brochure details the safety rules, dress, personal

The inducted person escorting the visitor is responsible

Visitors to site will be required to wear a high visibility

General Site Safety Rules

1. Casting Plant 2. Potrooms

ID NO: CARD NO: PASSPORT NO: __