CODE OF PRACTICE 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.