Hydrocarbon and hazardous goods infrastructure and management audit

Audit against AS 1940-2004 The storage and handling of flammable and combustible liquids

• Inspection area

• Site

• Conducted on

  Date

• Prepared by

• Location
  Address

• Inspection team

1. Introduction and scope

• This audit has been requested by Bruce Christian for Sherwin Iron and undertaken by Les Payne, Health, Safety and Environment Manager for Balmoral Mining and Construction.
  The intent of this audit is to do a gap analysis on the infrastructure and management practices concerning the storage and handling of flammable and combustible liquids, stored and/or handled by Balmoral Mining and Construction on the Sherwin Iron mine site, against the Australian Standard 1940-2004.
  Only clauses in the standard relevant to the operation have been considered.
  This audit does not cover systems and processes relating to the management of all classes of dangerous goods. The standard makes reference only to the storage and handling of class 3 flammable liquids and combustible liquids.
  

2. Details of existing hazardous substances / combustible liquids on site

• Are there class 3 flammable liquids stored on site?

  Yes

  No

  N/A

• Details of Class 3 flammable liquids on site, volumes stored, expected annual use

Class 3 Hazardous liquid

• Substance name: Volume stored: Expected annual use

• Are there class C1 or C2 combustible liquids stored on site?

  Yes

  No

  N/A

• Details of Class C1 or C2 combustible liquids on site, volumes stored, expected annual use

Class C1 or C2 combustible liquid

• Substance name: Volume stored: Expected annual use

3. Storage of flammable and combustible liquids

• Are there flammable or combustible liquids stored on site that meet the criteria of "minor storage"

  Yes

  No

  N/A

• "Minor storage" refers to quantities allowable as minor storage as referenced in Section 2 AS 1940-2004

• Are there flammable or combustible liquids stored on site in greater quantities than deemed to be "minor storage"?

  Yes

  No

  N/A

• This question applies to flammable or combustible liquids that are stored in greater quantities than those classified in Section 2 AS 1940-2004

4. Minor storage

• Are minor storage areas located inside or outside

  Inside

  Outside

• Is the indoor storage facility located in a position that does not jeopardise the safety of persons or impede firefighting operations in any areas of the building (or basement) due to spilt liquids or vapours?

  Yes

  No

  N/A

• Is the indoor storage facility adequately ventilated?

  Yes

  No

  N/A

• Minor storage locations

Minor storage location

• Storage type: Location on site: Substance(s) stored:

• Picture

  Media

5. Minor storage tanks

• Does the tank comply with AS 1692 and is there evidence that the tank has been inspected and maintained regularly?

  Yes

  No

  N/A

• Does the fill point to the storage tank comply with the following requirements?

• The fill point is readily accessible?

  Yes

  No

  N/A

• The fill point is protected from accidental damage?

  Yes

  No

  N/A

• The fill point is located so that a tank vehicle is not required to enter the tank compound to make a delivery?

  Yes

  No

  N/A

• A gauge is located on the tank that monitors the amount of liquid in the tank?<br>The gauge also shows the safe fill capacity of the tank?

  Yes

  No

  N/A

• The fill point is in open air, at lease 2 metres from a building entrance and 3 metres from an ignition source

  Yes

  No

  N/A

• Storage tank is separated from on site protected places as per Table 5.4 AS 1940-2004

  Yes

  No

  N/A

• Have provisions been made to contain leakage or spillage from the tank storage facility

  Yes

  No

  N/A

6. General requirements relating to storage of flammable or combustible liquids that are stored in greater quantities than those classified as minor storage

6.1 Design safety and suitability

• Is the installation designed and constructed so that it is safe and suitable for the conditions of use?
  Have the following factors been considered?

• Working pressure and structural stresses?

  Yes

  No

  N/A

• Heat, corrosion, or attack by the liquid being handled?

  Yes

  No

  N/A

• Site conditions, such as topography, usage of adjoining areas, or the risk of natural disasters, eg flood, earthquake, lightening strikes

  Yes

  No

  N/A

• Design of plant, equipment, and operating methods, so as to minimise fire and accident risks and the possibility of errors or misunderstandings of staff?

  Yes

  No

  N/A

• Specific design for emergencies?

  Yes

  No

  N/A

• The identification and function of valves, switches or control actuators?

  Yes

  No

  N/A

• Safe access to and egress from all working locations?

  Yes

  No

  N/A

• Avoidance of ignition systems?

  Yes

  No

  N/A

• Ventilation for vapour disposal?

  Yes

  No

  N/A

• Separation of potential hazards, including areas where activities cannot be controlled?

  Yes

  No

  N/A

• Spill control measures to avoid contamination of soil and water?

  Yes

  No

  N/A

• Has the installation been designed to facilitate the management of an emergency, taking into account:<br>(a) the nature and quantity of the liquids stored<br>(b) the layout of the storage area<br>(c) the access through or around walls or other barriers<br>(d) the type and construction of any buildings<br>(e) the type and means of any fire protection system

  Yes

  No

  N/A

6.2 Minimisation of vapour hazards

• Is ventilation, extraction or dispersal provisions sufficient to maintain exposure levels below exposure standards.

  Yes

  No

  N/A

6.3 Separation distances

• Are storages separated from boundaries, ignition sources, protected places, and accumulation of combustible materials by the minimum distance relevant to each type of storage as specified in Clauses 4.3 and 5.7 of AS 1940-2004

  Yes

  No

  N/A

• Are storages located in close proximity to other specified dangerous goods and if so, are separation distances in place that are specified in the ADG code

  Yes

  No

  N/A

6.4 Lighting

• Where storages are operated at night, is there sufficient lighting to provide safe working conditions?

  Yes

  No

  N/A

6.5 Security, signs and notices

• Does any storage area greater than minor storage display the following signs?

• DANGER - NO SMOKING, NO NAKED FLAMES

  Yes

  No

  N/A

• For flammable liquids - a class label and subsidiary risk sign

  Yes

  No

  N/A

• For combustible liquids - a COMBUSTIBLE LIQUID sign

  Yes

  No

  N/A

• Does the entrance to the premises display the following signs:

• A WARNING - RESTRICTED AREA - AUTHORISED PERSONNEL ONLY sign

  Yes

  No

  N/A

• The name address and phone number of the occupier

  Yes

  No

  N/A

• A layout showing the location of fixed fire protection facilities (where installed), the drainage system and the "Emergency Stop" switch?

  Yes

  No

  N/A

7. Requirements for above ground tanks with integral secondary containment.

Secondary containment type

• Picture

  Media

• Does the tank comply with AS 1692 and is there evidence that the tank has been inspected and maintained regularly?

  Yes

  No

  N/A

• The secondary containment is adequately designed to contain the entire contents of the primary tank?

  Yes

  No

  N/A

• Is there at least 3 metres separation between an interstitial space of the tank and any ignition source, including vehicles being refuelled?

  Yes

  No

  N/A

• Is the tank capable of resisting damage from the impact of a motor vehicle?

  Yes

  No

  N/A

• Is there a means to release liquid by siphon from the tank?

  Yes

  No

  N/A

• Is the tank fitted with a means of determining its contents?

  Yes

  No

  N/A

• Does the tank have overflow protection?

  Yes

  No

  N/A

• Does each fill point have spill containment of at least 15 litres?

  Yes

  No

  N/A

• Storage tank is separated from on site protected places as per Table 5.4 AS 1940-2004

  Yes

  No

  N/A

8. Fuel dispensing

8.1 General requirements

• Does the dispensing tank have a clearly identifiable emergency shut off provision?

  Yes

  No

  N/A

• Are the following signs prominent on or near the dispenser?<br>STOP ENGINE - NO SMOKING

  Yes

  No

  N/A

8.2 Hazardous zones

• Has a hazardous zone for the dispenser been identified?

  Yes

  No

  N/A

8.3 Dispensers

• The dispenser is located in a place that minimises the possibility of damage from vehicles

  Yes

  No

  N/A

• Is there a system to ensure that no fixed, portable or mobile ignition sources are present within a designated hazardous zone except for a vehicle entering or leaving the dispensing area?

  Yes

  No

  N/A

• Does any area where a vehicle can stand whilst being refuelled, drain into an area where it can be contained?

  Yes

  No

  N/A

8.5 Delivery hoses and nozzles

• Is the nozzle designed so that fuel flow to the nozzle is shut off and remains shut off if the nozzle is dropped from a height of 250mm

  Yes

  No

  N/A

• Does the delivery nozzle incorporate a device that automatically shuts off fuel flow to the nozzle when the level of the liquid reaches the end of the nozzle?

  Yes

  No

  N/A

• Does the nozzle incorporate a safety device so that fuel is cut off if the nozzle spout is tilted above horizontal from its operating position?

  Yes

  No

  N/A

• If the dispenser has a quantity or preset facility, the dispensing nozzle must not have a latching device

  Safe

  At Risk

  N/A

8.6 Records

• Are records kept of liquids received, stored and dispensed?

  Yes

  No

  N/A

8.7 Procedures

• Do operating procedures take into account the following?

• The need to switch off a vehicles engine while refuelling?

  Yes

  No

  N/A

• The prevention of overfilling and spillage when storage tanks are being replenished?

  Yes

  No

  N/A

• The suitability of containers being filled at dispensers for use?<br>ie container condition and material, the presence of an effective cap, correct labelling and that containers shall not be filled when inside a vehicle compartment.

  Yes

  No

  N/A

• Procedures to be followed in the event of spillage?

  Yes

  No

  N/A

• Training in the use of emergency equipment?

  Yes

  No

  N/A

• Maintaining appropriate records

  Yes

  No

  N/A

9. Operational and Personnel safety

9.1 General precautions

• Does the occupier have a process to control the entry to the installation and ensure those who do require entry, are adequately inducted?

  Yes

  No

  N/A

• Does the occupier ensure that vehicle access to and within the restricted area is controlled?

  Yes

  No

  N/A

• Are there signposted speed limits where appropriate?

  Yes

  No

  N/A

• Are vehicles parked in designated parking places and comply with any operating and emergency procedures?

  Yes

  No

  N/A

• Is there a process to ensure the area within any compound or store is maintained in a safe condition, specifically:<br>(a) the area is kept free of extraneous materials<br>(b) specified clearance distances are maintained at all times<br>(c) packages shall not be placed where they could jeopardise entry or exit<br>(d) spills are cleaned up as soon as possible

  Yes

  No

  N/A

• Are bunds maintained and checked regularly so as to be kept free of extraneous combustible material and that they have retained their designed capacity?

  Yes

  No

  N/A

• Is there a process to ensure that any self-closing door to a store or cabinet shall not be propped open?

  Yes

  No

  N/A

• Has a hazard identification and risk assessment been undertaken to ensure that appropriate controls are in place?

  Yes

  No

  N/A

• Are MSDS describing the properties of the liquids being kept or handled in the installation and appropriate first aid measures readily available?

  Yes

  No

  N/A

9.2 Operating procedures

• Safe systems of work, including procedures commensurate with the quantity and nature of the liquids kept, shall be developed, documented and implemented.
  Does the occupier have written procedures appropriate to the installation that include the following?

• A site plan indicating tanks, plant, pipe work, switchboards, or substations, emergency stop valves, fire protection systems and drainage?

  Yes

  No

  N/A

• Operating instructions, covering all aspects of the day to day operation of the installation?

  Yes

  No

  N/A

• Maintenance procedures, covering regular testing, inspection and monitoring of the equipment?

  Yes

  No

  N/A

• Emergency procedures, covering actions to be taken in the event of fire, spillage, accident, equipment failure or other emergencies?

  Yes

  No

  N/A

• Is there evidence that all personnel are trained in the appropriate procedures?

  Yes

  No

  N/A

• Is there a process to ensure all personnel comply with procedures established for the installation?

  Yes

  No

  N/A

• Are procedures regularly reviewed and modified as necessary?

  Yes

  No

  N/A

9.3 Management of leaks and spills

• Are there clean up materials available on site in the event of a leak or spill?<br>ie: spill kits, waste recovery drums, shovels and brooms

  Yes

  No

  N/A

• Are there procedures to deal with leaks or spills?

  Yes

  No

  N/A

• Does the emergency plan covering leaks or spills give reference to notifying the emergency services if required?

  Yes

  No

  N/A

9.4 Placarding

• Is every storage facility in which flammable liquids kept, placarded accordingly?

  Yes

  No

  N/A

9.5 Safety information

• Does the occupier have available safety information, principally for emergency services?

  Yes

  No

  N/A

9.6 Construction and maintenance work

• Does the occupier ensure that no maintenance work is carried out in any store or cabinet in which flammable or combustible liquids are kept without written authorisation?

  Yes

  No

  N/A

• Does the occupier have in place a work permit system for undertaking work that is not routine or non-hazardous?

  Yes

  No

  N/A

9.7 Personnel training

• Are all personnel who handle flammable or combustible liquids fully conversant with the relevant MSDS and applicable safety regulations and safe handling procedures?

  Yes

  No

  N/A

• Are all contract personnel who handle flammable or combustible liquids fully conversant with the relevant MSDS and applicable safety regulations and safe handling procedures?

  Yes

  No

  N/A

• Are all persons whose work involves handling flammable or combustible liquids educated on good hygiene practices as listed in AS 1940-2004

  Yes

  No

  N/A

• Are records kept for the following?

• Training and retraining

  Yes

  No

  N/A

• Equipment tests required by AS 1940-2004 and it's referenced documents

  Yes

  No

  N/A

• In-service inspections

  Yes

  No

  N/A

• Drills (6 years)

  Yes

  No

  N/A

• Maintenance and repairs

  Yes

  No

  N/A

• Fires, significant spillage, accident, injury, dangerous occurrence or other incident

  Yes

  No

  N/A

9.8 Personal protective equipment

• Where flammable or combustible liquids are kept or handled, are all persons provided with the appropriate personal protective equipment?

  Yes

  No

  N/A

9.9 First aid

• Does the site have a first aid station with an appropriate first aid kit and first aid instructions?

  Yes

  No

  N/A

• Does the site have at least 1 person who is trained to administer first aid and a list of persons responsible for administering first aid displayed on notice boards throughout the premises.

  Yes

  No

  N/A

10. Emergency management

• Has the site prepared a detailed plan for combating emergencies that could occur on-site.

  Yes

  No

  N/A

• Does this plan take into account any potential for the occurrence of fire, explosion, natural disaster or release of dangerous goods?

  Yes

  No

  N/A

• Is the plan appropriate to the size and complexity of the installation, it's resources and personnel?

  Yes

  No

  N/A

• Has this plan been made familiar to all site personnel?

  Yes

  No

  N/A

• Is this plan periodically reviewed?

  Yes

  No

  N/A

• Is a manifest provided and maintained?

  Yes

  No

  N/A

11. Fire protection

• Are fire protection systems appropriate (based on a risk assessment) to the hazard and include consideration of adjoining activities and materials, so as not only to deal with incidents within the storage, but also to reduce the potential for the liquids to become involved through the escalation of another incident?

  Yes

  No

  N/A

• Is the location of firefighting equipment reasonably adjacent to the risk being protected?

  Yes

  No

  N/A

• Are fire extinguishers labelled in accordance with the relevant Australian Standard?

  Yes

  No

  N/A

• Is there a system in place to inspect and test fire protection equipment

  Yes

  No

  N/A

• Sediment levels kept at a minimum?

  Safe

  At Risk

  N/A

• Is overall house keeping ok?

  Safe

  At Risk

  N/A

12. Waste storage and disposal

• Is there a system for the safe storage and disposal of wastes, spills, damaged containers and items contaminated with flammable or combustible materials?

  Yes

  No

  N/A

• Is there a process that ensures that waste is not allowed to accumulate before having it removed?

  Yes

  No

  N/A

Comments

• Further comments relating to this audit

Sign off

• Health, Safety and Environment Manager Balmoral Mining and Construction

  Sign

• Project Manager Sherwin Iron

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