RICHARDS BAY MINERALS Effective Date: 31 July 2017
APPLICABLE TO COP NO. REVISION NO PAGE All Divisions 13 M 2 1 of 11
MANDATORY CODE OF PRACTICE ON EMERGENCY PREPAREDNESS AND RESPONSE
Compiled by : Manager: Security Services
1. PURPOSE The COP was drawn up in accordance with the DMR Guideline Ref. No. 16/3/2/1-A5 issued by the Chief Inspector of Mines and is implemented at RBM.
This is a mandatory COP in terms of section 9(2) and (3) of the MHSA.
The COP may be used in accident investigation/enquiry to ascertain compliance and also to establish whether the code is effective and fit for purpose.
All managerial instructions, recommended procedures and standards on relevant topics comply with the COP.
The COP supersedes all previous relevant COP’s.
2. DEFINITIONS
COP - Code of Practice
SOP - Standard Operating Procedure
MHSA - Mine Health and Safety Act
DMR - Department of Mineral Resources
BRRP - Business Resilience and Recovery Plan
SHEQ - Health, Safety, Environment & Quality
HR - Human Resources
ERP - Emergency Response Plan
FARB - Fire and Rescue Brigade
SQRA - Semi Quantitative Risk Assessment
SANS - South African National Standards
HIRA - Hazard Identification and Risk Assessment
HSE - Health Safety and Environment
This copy is valid for 17 April 2018 COP 13M REV NO: 2 PAGE 2 of 11
SOP - Standard Operating Procedure
SEP - Standard Engineering Procedure
HR - Human Resources
CCR - Corporate and Community Relations
NFPA/FPA - (National) Fire Protection Association
PM - Planned Maintenance Records
CCTV - Closed Circuit Television
3. MEMBERS OF THE DRAFTING COMMITTEE Name Designation/Affiliation N Swart General Manager: HSE&S T Govender Manager: Health and Safety T Motlhaba Manager: Legal and Admin Services E Selemane Manager: Security Services B KIhn Superintendent: Safety (Acting) M Nxumalo Full Time Health & Safety Representative – Final Products L Mlondo LM Fire Services (Chief Fire Officer) E Zakwe Health & Safety Steward - NUM A Yengwa Full Time Health & Safety Representative – Mine
4. GENERAL INFORMATION 4.1 Description and Location of Mine Richards Bay Minerals (RBM) is a subsidiary of Rio Tinto, was established in 1976 to mine, process and market naturally occurring heavy minerals. RBM is located in northern KwaZulu-Natal, adjacent to the Indian Ocean coastline approximately 20km north-east of Richards Bay. RBM has four mining plants currently in operation on the coastal dunes, and sophisticated processing and smelting plants adjacent to its Richards Bay Office complex approximately 7kms inland.
This copy is valid for 17 April 2018
COP 13M REV NO: 2 PAGE 3 of 11
Fig 5.1 – Map of General Location
4.2 Commodities Produced Commodities produced are Titania Slag, Pig Iron and various grades of Rutile and Zircon.
4.3 Mining Method and Mineral Excavation Process
The mining method involves dredge and dry mining the sand dunes and the on-board wet separation of concentrates. The heavy mineral concentrate (HMC) extracted from the dunes contains Ilmenite, Zircon and Rutile. The HMC is transported to the Smelter site and following further gravity and magnetic separation, the Ilmenite is smelted to form Titania slag and high purity Iron. Rutile and Zircon are treated in a Mineral Separation Plant using a combination of wet gravity, magnetic and high tension separation to produce various grades of final mineral products.
Levels of Emergency Level one – A minor site incident within a departmental area that is unlikely to spread and which can be contained and made safe by RBM emergency response. Generally accepted as located in one plant on site. Level two – A more serious incident affecting a whole plant and/or an adjacent plant but unlikely to have off-site consequences. This emergency may be dealt with by the RBM emergency response team with or without the support of outside agencies. Level three – A major incident affecting the site and/or surrounding areas. This type of emergency would require an RBM emergency response team supported by outside agencies which may initiate the Business Resilience and Recovery Plan.
This copy is valid for 17 April 2018
COP 13M REV NO: 2 PAGE 4 of 11
5. RISK MANAGEMENT (HIRA) A structured system for identifying and rating the significance of HSE risks exists at RBM. This system establishes the framework for a continual improvement program.
Initial review
Management Commitment &
review Policy Continuous Improvement
Cycle Checking & Planning
corrective action
Implementation &
Operation
The purpose of this standard is to ensure that SHEQ hazards are identified; risks associated with these hazards are evaluated and managed. Every employee and contractor need to be familiar with work related hazards, its associated risks and control measures.
This standard is based on the Rio Tinto SHEQ Management standard Element 3: Hazard Identification and Risk Management (HIRA) which consists of three tiers:
Level 1 – Pre-task hazard assessment (task/job based) is the assessment of hazards and controls associated with a job prior to performing any job and must be formally (documented) e.g. HIRA but may be supplemented by a Take 5. Level 2 – Qualitative risk assessment is the application of a qualitative risk analysis technique, which provides an efficient and effective team-based method of identifying and analysing single risk issues (hazards, aspects or opportunities), and assigning controls using the 5x5 risk matrix . Level 3 – Semi quantitative risk assessment typically involves detailed numerical estimates of risk, by combining a detailed analysis of potential consequences and the likelihood of those consequences occurring.
Hazard identification and risk management must be applied to the following activities but is not limited to the activities listed below: All operational tasks All maintenance tasks Exploration and project development Conceptual studies Order of magnitude studies Pre-feasibility studies Engineering Procurement Construction Commissioning Closure
This copy is valid for 17 April 2018
COP 13M REV NO: 2 PAGE 5 of 11
Technical effectiveness of Emergency Preparedness is evaluated and addressed through periodic mock drills related to our Business Resilience and Recovery Plan (BRRP) and Emergency Response Plan (ERP) as well as localized emergency evacuation drills within the various sections and departments.
Ongoing hazard identification and risk assessment, done by plant personnel and line personnel and the emergency procedures reviewed every three years or when changes take place.
6. EMERGENCY PREPAREDNESS MEASURES
6.1 Detection and Early Warning Systems
6.1.1 Fire
All installations will comply with RBM’s fire protection specifications. All equipment installed at RBM is purchased, installed and maintained in accordance with relevant SANS, NFPA codes and RBM’s Insurers requirements.
Fire equipment and control systems are installed to meet the needs of fire risk assessments carried out in each division. All installations are inspected on a planned maintenance schedule and maintained as required. All servicing and maintenance is done by a SANS 1475 approved on site service provider.
Ziton fire detection and alarm systems have been installed in all critical areas for early detection and warning. These systems are monitored at the Fire Station and the Main Sub Station on a 24hour basis.
All high risk installations have been fitted with fire suppression systems that are linked to the fire detection system for quick response.
6.1.2 Other
The following production areas where potential CO Gas emergency situations may exist are fitted with automated early warning alarms to indicate potential emergencies: Smelter Slag Plant Iron Plant Mineral Separation Plants Roaster Tails Treatment Plant Co Gas Plant.
Where required, all employees working in these are all issued with personal CO Gas Monitors.
Early warning detection systems have also been fitted in administrative office blocks and workshops in the vicinity of the abovementioned production areas as follows: Central Maintenance Workshops (CMW) and Offices Smelter Production Offices Smelter Workshop
This copy is valid for 17 April 2018
COP 13M REV NO: 2 PAGE 6 of 11
RBM has a Closed Circuit Television System (CCTV) consisting of approximately 400 strategically placed CCTV Cameras which are monitored on a 24 Hour basis at a Central Command Centre. The CCTV System can be used to identify and monitor potential emergency situations.
6.2 Communication Systems
Richards Bay Minerals has a dedicated radio channel for use in the event of an emergency situation. There are four communications towers within the mine area which ensure sufficient coverage via cellular phone and two way radio. These are all fitted with emergency back up power supplies in the event of there being a power outage. RBM has a dedicated centralised call centre that is manned 24 hours a day. An emergency telephone number: 3333, is used for all emergency situations and displayed on notice boards and in all control rooms within the various plants.
6.3 Emergency Medical Care
During normal working hours RBM has an on site Clinic which is capable of dealing with emergencies, including trauma. Depending upon the severity of the injury, the doctor or the emergency response team will decide whether the case will be handled at the facility or referred to a hospital.
RBM has a Fire and Rescue Brigade, which is manned 24 hours a day. FARB is equipped with two ambulances and two emergency response vehicles capable of attending to all emergency medical situations.
6.4 Mine Evacuation and Escape Procedures
Procedures are developed to cover all potential emergency situations at RBM. These procedures include chains of command, communications, alarms, shut down and evacuation procedures, emergency drills, dedicated equipment and handling of medical emergencies. Lists of emergency procedures are available, divisionally.
Emergency related procedures are reviewed at least every 3 years and following a relevant injury, incident, emergency situation or drill. Emergency evacuation drills and fire fighting procedures are formally tested, reviewed and recorded annually. An emergency response plan has been prepared and the following situations have been identified from the BRRP as potential level three incidents: Transportation – fires or spillage including: Flammable liquids & gases / compressed gases / sulphuric acid / caustic soda / calcium carbide / lime / cryogenics Storage and handling – fires or spillage incidents involving the above Structure fires & explosions CO gassing, fires & explosions Major Environmental pollution Major Safety Incident/Accident
All buildings and plants have formalized emergency evacuation routes with adequately identified emergency assembly points. This copy is valid for 17 April 2018
COP 13M REV NO: 2 PAGE 7 of 11
6.5 Training and Awareness
All contractors and RBM employees allocated to work within an operational process area must complete and be found competent in the plant specific SHEQ training requirements for that area. This training program includes specific training relating to potential emergency conditions and response procedures. The training is conducted every three years.
7. EMERGENCY RESPONSE MEASURES
7.1 Rescue and Response Capabilities
RBM maintains an adequately staffed and competent fire and rescue brigade, capable of dealing with potential level two emergency and medical situations, on a 24-hour basis, together with a dedicated fire engine, ambulance and all necessary related equipment.
Use of the fire and rescue brigade (&/or equipment) for services other than emergency must be authorized by the Main Security Services. Such services include standby duties during high risk activities such as working at heights or confined spaces.
RBM maintains an adequately staffed and competent contract security service capable of providing total site access control on a 24-hour basis. This security service is available for emergency assistance.
7.2 Management of Emergencies
RBM has a detailed disaster management plan (BRRP) to include resource preparedness to respond to potential crisis incidents. This covers aspects such as: A detailed emergency response manual Templates for use in the event of an emergency Emergency scenarios and response plans Emergency notification procedures Emergency contact detail The establishment of a disaster management team – with clearly defined roles and responsibilities Plan administration and review and training, testing and evaluation procedures
7.3 Reporting and Recording
All actual emergency situations, evacuations and drills will be recorded and reviewed after the event for effectiveness. All incidents will be captured on RBM’s Incident Management System and investigated where required.
Planned maintenance records for all emergency equipment are maintained on RTBS and calibration and service records are kept at the various plants.
This copy is valid for 17 April 2018
COP 13M REV NO: 2 PAGE 8 of 11
8. IMPLEMENTATION AND COMPLIANCE
8.1 Legislative Standards The Mine Health & Safety Act No. 29 of 1996
8.2 Relevant SOP’s and Codes of Practice T13 GP 001 Emergency Response T13 GP 002 Medical Response Business Resilience and Recovery Plan COP 11 Non Conformance, Incident and Injury Reporting and Recording. E14 GP 001 Maintenance Work on Fire Protection Systems COP 56 CO Gas Safety
8.3 Roles & Responsibilities
8.3.1 Fire Protection Systems The Reliability Engineer – Fire Systems is responsible for design, installation, modification and maintenance for all fire protection systems and equipment.
8.3.2 Fire Equipment and Control Systems
The General Manager HSE&S is responsible to liaise with the RBM insurance consultants and schedule fire risk assessments as required by the RBM insurers and to ensure that approved recommendations are actioned. The Chief Fire Officer is responsible to carry out and maintain Fire Risk Assessments for all Divisions at RBM. The various 7(4) Appointee and 2.13.3.1 Appointees are responsible to inspect all fire protection systems and equipment, installed in their area of responsibility, on a regular basis and report any deviations immediately to the Officer – Fire Chief.
8.3.3 Emergency Procedures
The 7(4) Appointees and 2.13.3.1 Appointees are responsible to develop appropriate Standard Operating Procedures (SOP’s) and Standard Engineering Procedures (SEP’s) to cover all potential emergency situations within their areas of responsibility and to ensure that all employees working in these areas, are trained competent in those procedures. They must ensure that these procedures include chains of command, communications, alarms, shut down and evacuation procedures, emergency drill, dedicated equipment and handling of medical emergencies.
The 7(4) Appointees and 2.13.3.1 Appointees are responsible to ensure that lists of emergency procedures are available departmentally, reviewed every three years and following a relevant injury, incident, emergency situation or drill. They must ensure that emergency evacuations, drills and fire fighting procedures are formally tested not less than once a year. All formal records must be available in the departmental SHEQ system records.
8.3.4 Emergency Procedure Training
The 7(4) Appointees and 2.13.3.1 Appointees are responsible to ensure that all contractors and RBM employees working in their areas of responsibility are trained and competent, in the relevant plant specific SHEQ training requirements for that area, basic fire extinguisher use and plant and site evacuation.
This copy is valid for 17 April 2018
COP 13M REV NO: 2 PAGE 9 of 11
The Chief Fire Officer is responsible to develop training modules for the operation of the various fire extinguishers installed at RBM.
8.3.5 Emergency Response Plan
The Superintendent Safety is responsible to compile and maintain an emergency response plan for the RBM site to include resource preparedness to respond to potential level three severity incidents. The plan shall include individual procedures to cover identified situations where applicable.
8.3.6 RBM Fire and Rescue Brigade
The Manager Security Services is responsible to maintain an adequately staffed and equipped fire and rescue brigade, trained competent to deal with potential level one, two and three emergency and medical situations on a 24-hour basis. Response equipment will include an operationally equipped and manned ambulance and fire engine.
The Manager Security Services is responsible to authorise approval for any use of fire and rescue brigade (and/or equipment) for service other than emergency.
8.3.7 Incident Management T13 GP 001 – SHEQ Emergency Response refers. The affected line manager will take control of his plant to effect emergency isolation and recovery work, using the Chief Fire Officer to provide technical emergency support and information of the status and resources at his disposal.
8.3.8 Evacuation of Personnel The 7(4) Appointees and 2.13.3.1 Appointees are responsible to ensure that procedures are in place to identify emergency situations and to initiate an orderly evacuation of areas under their control, as and when required.
8.3.9 RBM Security Service The Manager Security Services is responsible to engage, control and maintain an adequately staffed security service competent to provide total site access control on a 24- hour basis. This security service shall be available and competent to provide necessary assistance and additional security in emergency situations. Security will man the central command center and route the reporting of relevant incidents to the FARB team and maintain a log of communications during the incident.
8.3.10 Emergency Communications The General Manager Corporate and Community Relations (CCR) is responsible to immediately attend the site of any crisis and to gather necessary information from the relevant General Manager. Based on liaison with other General Managers he/she will authorise the release of information to the press and stakeholders. He/She will act as principal Company spokesman to the media. This will involve preparing press releases for Managing Director approval, attending press conferences and issuing press releases. He/She will also control all aspects of Public Relations work including controlled response to telephone enquiries and the practical issues concerning the flow of information generated by the incident. The Superintendent Safety is responsible to ensure that the regulators have been contacted by the relevant Section 3.1(a) Appointee and the incident reported according to statutory requirements.
This copy is valid for 17 April 2018
COP 13M REV NO: 2 PAGE 10 of 11
The Managing Director is responsible to decide if an incident warrants being classified as a crisis requiring media involvement and to approve all draft communication prepared by CCR prior to external release. The relevant General Managers are responsible to collate, liase and provide information regarding any crisis situation within his/her area of responsibility to the General Manager CCR. The General Manager Human Resources (HR) is responsible to see that the relevant HR Business Partner and the HR Officer: Administration maintains details of the employees’ next- of-kin, on a database available at all times. The GM HR will ensure that the families of injured employees are contacted, and counseled during the emergency.
8.4 Audit Audit of the following systems will indicate compliance status: COP 13M – Mandatory Code of Practice on Emergency Preparedness and Response Departmental SOP’s & SEP’s, Departmental SHEQ records including record of Emergency Drills HR training records Incident records and reports Emergency Response Plan Business Resilience and Recovery Plan and associated documents CCR media release records HR internal communications records Fire Systems Maintenance Records and PM’s CO Gas Detectors Maintenance and Calibration Records
9. ACCESS TO THE COP AND RELATED DOCUMENTS All documents are available on an electronic document management system or may be obtained from the Superintendent Safety via a request to the relevant General Manager.
10. REVISIONS
REV DESCRIPTION PAGE (S) DATE NO 0 New document. COP 13 rewritten to meet the All September requirements of the DMR Guideline for the 2011 compilation of a Mandatory Code of Practice for Emergency Response and Preparedness. 1 General review – no changes. Included Chairperson: All August 2013 Central HSE Committee in approval table. 2 Minor changes with regards to Designations/Title All April 2017 changes.
This copy is valid for 17 April 2018
COP 13M REV NO: 2 PAGE 11 of 11
11. APPROVAL Official Signature General Manager: HSE&S
Manager: Health and Safety
Manager: Legal and Admin Services
Manager: Security Services
Superintendent: Safety
Chief Fire Officer
Full Time Health & Safety Representative – Smelting & Processing
Full Time Health & Safety Representative – Mining
Union Representative - UASA
Union Representative - NUM
Chairperson: Central HSE Committee
This copy is valid for 17 April 2018