FRCPSelf Assessment Template

HSEC TOOLKIT
FATAL RISK CONTROL PROTOCOLS

SELF-ASSESSMENT
Business Unit: Enter Business Unit Name Here

Site: Enter Site Name Here
Instructions For Completion
1 Only the fields shaded in yellow can be edited.

2 Enter the date the audit for each specific FRCP was completed in the "Date Completed:" field.
3 Enter the auditor's or approver's name in the "Completed/Approved By:" field.
4 The "Gap" fields shaded in Yellow are to be completed using the Code that represents the appropriate "Gap" Analysis for
each question. These are scored separately for BHP Billiton Employees in column E and for Contractors in Column C. If you
do not wish to make a distinction between the two, then use only column E.
5 If you wish, you can print the worksheets to complete them in manually in the field, however they must be completed and
submitted electronically.
6 If you have any questions, please contact Kay Fitzgerald on +61 3 9609 2728
FATAL RISK CONTROL PROTOCOL 1. LIGHT VEHICLES SELF-ASSESSMENT
Intent: To eliminate or minimise the risk of fatalities, injuries and incidents arising from the use of light vehicles in surface operations.
Note: This Protocol relates to all light vehicles used for BHP Billiton work related activity including BHP Billiton vehicles whether owned or leased, hire vehicles, private vehicles and contractor
vehicles etc.
Business Unit: Enter Business Unit Name Here Employees Scores are incomplete Date Completed: Insert Date Here
Site: Enter Site Name Here Completed/Approved By: Insert Name Here
GAP ANALYSIS - Assess Current Status Against Requirement and Record Result in Gap Columns E and C Scale Code %
Existing systems and procedures fully comply with or exceed requirements No Gap N 100%
Good compliance with the requirements, existing systems require minimal adjustment Low Gap 1 90%
Partial compliance with requirements, systems and procedures developed but not implemented Medium Gap 2 70%
Minimum compliance with requirements, there are no systems or procedures developed High Gap 3 20%
Requirement is not applicable Not Applicable N/A N/A
Gap
Type Requirement Questions Documented Evidence Physical Evidence Comments
E C
A 1. Vehicle selection shall be based on risk Are vehicle selections based Evidence of risk assessment Vehicles considered fit for
assessment taking account of tasks, application, on risk assessment? Are purpose, meet BHP Billiton
environment and roll over and crash worthiness these listed criteria used in the safety requirements and
ratings. assessment? perform well in crash
worthiness ratings (compared
to similar vehicle types).
A 2. Light vehicles shall have the following Is all of this safety equipment Policy in place outlining All vehicles observed to meet
minimum safety features: in place for all light vehicles? minimum vehicle requirements. the minimum safety
· seatbelts for all occupants; Are vehicles fitted with radio Is the roll over protection requirements.
· horn; communication systems? Can system accredited and if so by Observation of vehicles and
· effective windscreen wipers; light and heavy vehicles whom? discussion with drivers.
· roll-over protection for all 4WD vehicles; communicate via this system?
· cargo barriers and load restraints;· drivers side
airbag; and
· two-way radio communication at mine sites
which have a permanent radio communication
system for those vehicles operated on roads also
used by heavy vehicles.
A 3. Speed alarms or speed monitors should be Have speed monitors and Speed alarms or monitors are Observation of vehicles and
installed in all BHP Billiton light vehicles. alarms been fitted to all light included as a preferred option discussion with drivers.
vehicles? in vehicle acquisition
requirements.
A 4. Light vehicles shall not have seating that is Are side-mounted vehicle Policy/Rules Observations, discussion with
side mounted. seats banned on site? personnel and contractors
Does this also apply to
contractor’s vehicles?
A 5. A formal maintenance inspection and How often is preventative Evidence of formal inspection All light vehicles found to be in
preventative maintenance program shall be in maintenance carried out and and maintenance program good working order eg tyre
place for all BHP Billiton vehicles. by who tread and pressure, oil and
fluid levels, lights, etc
Page 2 of 72
vehicles etc.
Gap
E C
A 6. A system should be in place for positively How is this achieved? Is the standard of vehicle Observation of vehicles
identifying light vehicles. identification consistent across
all vehicles including
contractors?
Is the identification easily able
to be read from a reasonable
distance and is it able to be
seen from both the side, front
and rear?
A 7. Light vehicles should have: Do all light vehicles meet these These requirements are Observation of vehicles.
· high visibility cover; requirements? included as a preferred option What colour is the preferred
· reflective taping; Is this equipment checked in vehicle acquisition option for light vehicles?
· flashing light; during vehicle inspection and requirements.
· first aid kit; maintenance programs? Is training provided in relation
. fire extinguisher; to use of the first aid kit and
. survival or emergency equipment suitable fire extinguisher?
for the operating environment.
A 8. A change management process shall Is the site change Change management Are all vehicle modifications
accompany all vehicle modifications. management change process procedure acceptable in context of their
applied to vehicle modifications impact regarding even weight
distribution (effect on handling
dynamics), impact on vehicle
crash worthiness, roll over
propensity, etc
B 9. Seatbelts shall be used in all cases for all How is compliance with this Site policy, rules, site audit Observation and discussion
occupants. requirement monitored? results, etc. with personnel.
Page 3 of 72
vehicles etc.
Gap
E C
B 10. A pre-operation vehicle safety check and Are pre-operation and Log books/ site audit results Discussion with driver
familiarisation system shall be in place and used familiarisation checks Vehicles are observed to be in
by the driver. performed by the driver? sound roadworthy condition
Is any training provided to the
driver on how to perform this
check?
B 11. Systems shall be in place to ensure that Does the site have a vehicle Vehicle journey management Discussion with drivers and
risks associated with vehicle journeys are journey management system? system site personnel
managed and controlled. The systems shall Are these listed requirements
include, but not be limited to: addressed in the system?
· journey management plans in place prior to Is an off site vehicle
commencement of new or changed travel emergency scenario included
activities; in the site Emergency plan?
· identification and monitoring of the risks
associated with the number of journeys, routes,
intersections etc. to ensure that the overall
exposure is reduced to as low a reasonably
practicable (ALARP);
· assessment and communication of changed
environmental and road conditions at the time of
travel;
· provision to manage fatigue.
B 12. Light vehicle running lights should be left How is compliance with this Evidence of policy, rules, Observations
on at all times when the vehicle is in operation. requirement assessed? audit/check results?
B 13. Mobile phones, whether hands free or not, Is this site policy? Evidence of policy, rules, etc Observations and discussions
should only be used by the driver of a vehicle How is compliance to this with drivers and site personnel.
whilst the vehicle is stationary, and in a safe requirement monitored?
location.
Page 4 of 72
vehicles etc.
Gap
E C
B 14. Controls shall be in place to ensure the How is this achieved? Evidence of standard operating Observation of physical
safety of people working in roadways, including procedures, job safety analysis barriers and signage and
work in and around unexpected breakdowns. and risk assessments. discussion with personnel.
B 15. A site-based review of pedestrian Has a review of pedestrian Review and recommendations Observations
interaction, road design and layouts (including interaction between light
entrance and exit points, intersections and other vehicles, road design and
potential points of interaction between light layouts been undertaken?
vehicles and other mobile equipment) shall be What date was the review
conducted and updated when changes to layouts undertaken?
are required. Where possible, traffic segregation
should be used to separate pedestrians, light
vehicles and other mobile equipment.
B 16. A site based traffic management plan shall Does the site have a Traffic Traffic Management Plan Observation of vehicle
be in place including, but not be limited to the Management Plan that operations and roadways and
following: includes these listed discussions with drivers.
· setting of appropriate speed limits for vehicle requirements?
types and road surfaces;
· overtaking protocol;
· procedures for light vehicles entering hazardous
or restricted areas;
· clear communication protocols;
· standards for safe following distances, based on
operational circumstances and near sight (blind
spot) limitations of other mobile equipment;
· installation and maintenance of road traffic
control signs as appropriate to the work site; and
· parking procedures.
Page 5 of 72
vehicles etc.
Gap
E C
C 17. All employees, contractors and visitors Is there a site induction? Training Modules and training Discussion with contractors
shall be inducted in road safety and site vehicle Does each Department that records.
hazards. uses light vehicles have an Copy of induction
area specific induction?
Are contractors included?
C 18. A permit or certification system shall be in Do training modules exist for Register of licensed drivers. Field observations, discussion
place to ensure drivers are competent to drive on all light vehicles? with vehicle drivers.
site. In addition, a system shall be in place to How is operator competency
verify that operators of BHP Billiton vehicles have assessed?
a valid drivers license prior to operating BHP What is the frequency of
Billiton vehicles off-site. refresher training?
C 19. Behaviour based observations shall Are items related to light Observation checklist Discuss with observers to
include the operation of light vehicles. Any need vehicles included in Observation analysis reports check understanding.
for additional specific retraining should observation checklists? and follow-up Check quality of observations
incorporate the results of these observations.
C 20. A fit-for-work policy shall be in place, Does a job specification Job specification
incorporating defined action levels for drugs and containing fitness requirements Selection procedure
alcohol, and a fatigue management plan. exist for all jobs related to light
vehicles?
Do personnel selection
requirements include a fitness
for work requirement?
Page 6 of 72
FATAL RISK CONTROL PROTOCOL 2. SURFACE MOBILE EQUIPMENT SELF-ASSESSMENT
Intent: To eliminate the risk of fatalities, injuries and incidents arising from the use of surface mobile equipment.
Gap
E C
A 1. Surface Mobile Equipment shall have the Is all of this safety equipment Observations of surface mobile
following minimum safety specifications: in place for all surface mobile equipment discussions with
· seat belts for all occupants; equipment? operators
· adequate lighting (eg. headlights, tail, turn,
brake, strobe, flashing light);
· identified isolation/lockout point in accordance
with the Isolation Protocol;
· adequate walkways, railing, steps/grab handle
combinations and boarding facilities including an
alternative path of disembarking in case of
emergency
· extended front bumpers on mine haul trucks
or adequate collision avoidance technology
and/or procedures;
· reversing alarms;
· collision avoidance technology and/or
procedures;
· chock blocks;
· horn; and
· effective windscreen wipers
Page 7 of 72
Gap
E C
A 2. Surface mobile equipment should have the What percentage of surface Evidence of risk assessment Observations of surface mobile
following minimum safety specifications, unless mobile equipment is fitted with for exemption (if applicable) equipment in the field and
exempted by risk assessment: this equipment? discussion with operators.
· approved or certified roll-over protection;
· a fire suppression system capable of being
activated from both ground and cabin levels;
· two way radio communication;
· fall on protection;
· enclosed and tightly sealed air-conditioned
cabins, with consideration of requirements for
noise and dust suppression systems and
shatterproof glass;
· signage on the equipment that allows clear and
easy identification from a distance; and
· a method for transporting supplies and personal
items to and from the operator cabin to enable
drivers to continuously maintain three points of
contact whilst mounting and disembarking
equipment. (eg. a back pack or shoulder strap
bag).
A 3. Technological advances should be How is this achieved? Evidence of systems

considered for collision avoidance, safety implemented in field
management systems, fleet management and observations.
visibility improvement.
A 4. Design inspection and maintenance Is there a system for the Evidence of maintenance, Condition of road way
requirements should be in place for all roadways design, inspection and inspections and design
including collision protection of hazardous and maintenance of roadways? system.
critical plant and equipment. Risk assessments Evidence of risk assessment
should be carried out prior to any changes to prior to traffic changes.
traffic movements.
Page 8 of 72
Gap
E C
A 5. Layout of cabins should take into Are cabin reviews/upgrades Review reports, etc. contacts Observation of surface mobile
consideration the ergonomics of seating, operator complete for all surface mobile with suppliers. equipment. Discussion with
controls, and retrofitted devices. equipment? operators on ergonomics of
cabins
A 6. Fleet and control consistency should be How is the standardisation of Results of audits to check Observations and discussions
considered where possible to minimise operator controls achieved? compliance with operators
error when changing machines
B 7. Seatbelts shall be used in all cases for all Are all vehicles fitted with Site Policy Observations of surface mobile
occupants. seatbelts? How is compliance equipment in the field.
with this requirement
monitored?
B 8. A formal selection and acceptance process Are risk assessments Evidence of risk assessment
based on risk assessment shall be in place for all performed on new to site and
new (to site) and modified surface mobile modified surface mobile
equipment prior to commencement of work on equipment?
site.
B 9. Selection of equipment, and any Is the selection and Evidence of application change
modification, shall be subject to a rigorous modification of surface mobile management process.
change management process. equipment assessed using the
site change management
process?
B 10. A procedure and checklist system shall be Are pre-operation checks and Completed log books and audit Observation and discussion
in place for pre-operation inspection by the inspections undertaken for all results. with operators.
operator, including a brake functionality test, surface mobile equipment?
before commencing work. Log books shall be Are audits conducted to ensure
maintained and audited. the checks are carried out?
Page 9 of 72
Gap
E C
B 11. A procedure shall be in place to ensure How is this achieved? View procedure. Observation and discussion
surface mobile equipment only operates on Are risk assessments Evidence of risk assessments with operators
surfaces that are sufficiently stable so they are undertaken to ensure surface
within the limits of safe operation. mobile equipment operates
within manufactures
recommended limits?
B 12. A post-maintenance machine test shall be Are post maintenance tests Procedure, evidence of tests Discussion with maintenance
in place after scheduled or break down routinely conducted?
maintenance.
B 13. On the job risk assessments shall be Are risk assessments Evidence of risk assessments Observation and discussion
conducted as part of the planning process for performed for mobile and JSA’s with operators
surface mobile equipment operations, including equipment operations or when
maintenance activities. the scope of operations
change work change?
Is all non routine surface
mobile equipment work
covered by Job Safety
Analysis?
B 14. A dust and water management plan for Does a dust and water Dust and water management Observations of roads
roads, mining and haulage shall be in place. management plan cover all plan.
Consideration shall be given to extreme wet roads, does the plan include
weather and the issue of over-watering roads. over watering and extreme
weather conditions?
B 15. Parking standards shall include Do all surface mobile Parking standards Observation of parking areas
requirements for the immobilization of surface equipment-parking areas and compliance to standards.
mobile equipment (eg. chocking or trenching) and comply with the site
consideration for breakdown maintenance standards?
activities.
Page 10 of 72
Gap
E C
B 16. A maintenance and inspection program for Has critical equipment for Register of critical equipment
critical equipment and components shall be in surface mobile equipment Maintenance plans
place. been identified? How was this Inspections
done?
B 17. A site based traffic management plan Are all of these requirements Traffic Management Plan Observations of site traffic and
should be in place including but not limited to the included in the site traffic roads.
following: management plan? Discussion with operators
· setting of appropriate speed limits, and Is the plan regularly reviewed
installation and maintenance of road signage; to include key learnings from
· right-of-way rues (including over-taking significant incidents?
restrictions);
· access planning in areas identified as
hazardous and having significant associated risk;
· systems to control movement of mobile
equipment in areas accessible to pedestrians,
into and out of workshops, and for controls on
pedestrian and light vehicle movement around
mobile equipment;
· designated parking areas for heavy vehicles
and light vehicles including around maintenance
areas;
· systems to control approaching, refueling
parking, boarding, disembarking, and isolation by
production and maintenance crews. Equipment
operators or drivers shall be out of the cabin and
dismounted onto ground level when their direct
involvement with maintenance or servicing is not
required.
Page 11 of 72
Gap
E C
· guidelines for abnormal road conditions prior to
use (eg. rain, high winds) giving “go/no go”
criteria and stating the responsible person
fo+B12r this decision;
· clear communication procedures for interactions
between all vehicles;
· truck loading/unloading protocols – to avoid
material falling from vehicle;
· guidelines for wide or abnormal loads including
offsite transport; and· systems to control
equipment use within the vicinity of overhead
power lines.
B 18. Procedures should be in place which detail Is this clearly defined and Standard Operating Discussion with operators and
what maintenance an operator is allowed to included in Standard Operating Procedures. maintenance personnel.
perform and what maintenance personnel can Procedures and maintenance
operate under testing conditions procedures?
B 19. A tyre management system should be in How has this been achieved? Evidence of tyre management Observations of vehicles –
place to address issues including fire, heating, What percentage of mobile system. fitted with fire suppression
electrical contact and separations. surface equipment if fitted with systems
on board fire suppression
systems?
C 20. Recruitment and induction processes for Are these requirements for Evidence of requirements in
surface mobile equipment operators shall surface mobile equipment the recruitment and induction
encompass past work history, site testing, operators included in pre process.
comprehensive medical examinations and employment screening?
psychological testing.
Page 12 of 72
Gap
E C
C 21. Site and area induction of operators shall Is there a site induction? Training Modules and training Discussion with contractors
be performed prior to starting work in a new area. Does each Department that records
uses surface mobile equipment Copy of induction
have an area specific
induction? Are contractors
included?
C 22. A permit or certification system shall be in Do training modules exist for Register of licensed operators Field observations, discussion
place to ensure drivers are competent to drive on all surface mobile equipment? with vehicle and equipment
site. In addition, a system shall be in place to How is operator competency operators.
verify that operators of BHP Billiton vehicles have assessed?
a valid drivers license prior to operating BHP What is the frequency of
Billiton vehicles off-site. refresher training?
Are external license
requirements systematically
checked?
C 23. A fit-for-work policy shall be in place, Does a job specification Job specification
alcohol and a fatigue management plan. exist for all jobs related to
surface mobile equipment?
C 24. Behaviour based observations shall Are items related to surface Observation checklist Discuss with observers to
include the operation of surface mobile mobile equipment included in Observation analysis reports check understanding.
equipment. Any need for additional specific observation checklists? and follow-up Check quality of observations
retraining shall incorporate the results of these
observations
Page 13 of 72
FATAL RISK CONTROL PROTOCOL 3. UNDERGROUND MOBILE EQUIPMENT SELF-ASSESSMENT
Intent: To eliminate or minimise the risk of fatalities, injuries and incidents arising from the use of mobile equipment underground.
Gap
E C
A 1. Underground mobile equipment shall have Is all of this safety equipment Observations of underground
the following minimum safety specifications: in place for all underground mobile equipment
· roll-over protection for load haul dump mobile equipment?
machines;
· operator overhead protection (ie. fall on
protection system, canopy or cab structure);
· automatic reversing alarm;
· roof mounted flashing lights on light vehicles;
· seat belts and/or passenger restraints;
· fail to safe brakes;
· automatic or manual fire suppression system;
· restricted area and/or pinch point access
controls or guarding where practicable; and
· A device to automatically immobilise a vehicle in
the absence of operator actions. (the specific
design requirements for this system should be
determined using a risk assessment eg.
deadman type switch, automatic braking system).
A 2. Design, selection, maintenance, and use Is this in place for all remote Documented standards and Observations of underground
criteria shall be in place for all remote controlled controlled equipment? criteria for remote controlled remote controlled equipment in
equipment. equipment the field
A 3. Design and maintenance requirements shall Is there a system for the Evidence of maintenance, Condition and layout of
be in place for all transport roadways. design, inspection and inspections and design underground road ways
maintenance of underground system.
roadways?
Evidence of risk assessment
prior to traffic changes
Page 14 of 72
Gap
E C
A 4. Risk assessments shall be undertaken as Has a risk assessment been Evidence of risk assessments
part of the design, selection, commissioning, performed that includes all
operation, modification, and maintenance design, selection,
process for all underground mobile equipment commissioning, operation
modification and maintenance
of underground mobile
equipment?
A 5. A formal acceptance process shall be in Does the site have a formal Documented process Discussion with operators
place for all new (to site) and modified acceptance process that
underground mobile equipment prior to applies to all new and modified
commencement of work on site underground equipment?
B 6. A procedure shall be in place to ensure that How is this procedure Evidence of procedure, No. of Field observations discussion
mobile equipment stops to allow pedestrians to communicated across the site? underground pedestrian with underground personnel.
pass in underground roadways /vehicle incidents.
Are audits used to check
compliance?
B 7. All people underground shall wear reflective What recognised standards are Evidence of standards Field observations
clothing to a recognised standard (eg. Australian used to achieve this?
Standard for Reflective Clothing).
Page 15 of 72
Gap
E C
B 8. Parking rules shall be in place including, but Are all of these requirements Parking rules and SOP’s. Field observations
not limited to the following: included in parking rules and Results of compliance audits
· engine should be shut down before the operator standard operating
leaves the machine except where safe operating procedures?
procedures are authorised by the Senior Site
Executive and supported by documented risk
assessment;
· parking brakes shall be applied;
· wheels should be turned into the rib/wall or
chocked, and positioned as close to the rib/wall
as possible; and
· all lifting and elevating attachments lowered or
secured in the parked position when not in use.
B 9. A system shall be in place to identify the Is a system in place for the Maintenance plans and
maintenance and inspection requirements for maintenance and inspection of inspection schedules.
underground mobile equipment (including where underground equipment?
the mobile equipment should be located during
the work).
B 10. A process shall be in place for pre-use and Are pre-operation checks and Completed log books Observation and discussion
operational checks that clearly defines if inspections undertaken for all with underground operators
underground mobile equipment is safe to surface mobile equipment?
operate.
B 11. Controls shall be in place to ensure the Are risk assessments Evidence of risk assessments, Observations and discussions
safety of people working in roadways including performed? SOP’s and JSA’s. with underground operators.
work in and around unexpected breakdowns.
The risk to any attendant employees (eg. cable Are controls listed in Standard
handlers) shall be specifically addressed. Operating Procedures and job
safety analysis conducted for
non-routine work
Page 16 of 72
Gap
E C
C 12. A competency based training system shall Do training modules exist for Register of certified operators Field observations, discussion
be in place for operation and maintenance of all underground mobile with vehicle and equipment
underground mobile equipment equipment? operators.
How is operator competency
assessed?
What is the frequency of
refresher training?
C 13. Key behaviours necessary to carry out What key behaviours have List of key behaviours.
activities associated with mobile equipment safely been identified?
shall be identified How is adherence to these key
behaviours assessed?
C 14. A fit- for- work policy shall be in place, Does a job specification Job specification
alcohol and fatigue management plan. exist for all jobs related to
underground mobile
equipment?
C 15. Behaviour based observations shall Are items related to Observation checklist Discuss with observers to
include the operation of underground mobile underground mobile equipment Observation analysis reports check understanding.
equipment. Any need for additional specific included in observation and follow-up
retraining should incorporate the results of these checklists? Check quality of observations
observations.
Page 17 of 72
FATAL RISK CONTROL PROTOCOL 4. UNDERGROUND GROUND CONTROL SELF-ASSESSMENT
Intent: To eliminate or minimise the risk of fatalities, injuries and incidents arising from falls of ground and collapse in underground operations.
Gap
E C
A 1. Design and selection of equipment used in Are equipment specifications Ground control plan Observation of ground control
ground control applications shall meet the stated in the ground control equipment.
requirements specified in the ground control plan. plan?
How is compliance to these
specifications assessed?
A 2. The equipment design shall incorporate How is this achieved? Evidence of risk assessments Observation of equipment and
removal or separation of the operator from and evaluations of equipment discussion with operators
unsecured ground, or the equipment shall provide Are risk assessments to meet these criteria.
a physical barrier to protect the operator in the performed as part of the
event of an uncontrolled ground movement from equipment design process?
roof or walls.
A 3. Materials used in the ground support Are these requirements Ground control plan. Results of
system shall be selected and routinely tested to specified in the ground control tests
ensure they meet the required specifications of plan?
the ground control plan.
Are routine tests regularly
conducted to ensure these
specifications are met?
A 4. Equipment used in the ground control Is ground control equipment Ground control plan
system shall be maintained and tested on a regularly maintained and
regular basis to ensure that it meets the ground tested?
control plan requirements and specifications (eg.
longwall system health, torque settings for bolt
installation, etc.)
A 5. Advances in ground control technology Are monitored? Date of last engineering review View evidence of application.
shall be monitored, and appropriate engineering
reviews should be conducted to determine How are advances in ground Examples of applied
whether new technology should be implemented control technology assessed technology.
or used. for relevance at site?
Page 18 of 72
Gap
E C
B 6. Initial and ongoing geotechnical analysis How is this achieved?
and assessment shall be an integral part of the
mine design process and carried out by a
qualified and competent person(s).
B 7. As part of the change management Does the site have a formal Change management
process, geotechnical assessment shall be change management system procedure
undertaken during modification to the mine that includes geotechnical
operation or design. assessment and modification?
B 8. In developing, implementing or altering any How is this achieved? Evidence of risk assessments
ground control system a geotechnical risk prior to alterations.
assessment process shall be undertaken. Are geotechnical risk
assessments performed in line
with these requirements?
B 9. Adequate contingency in ground control Does this operation have a Evidence of plan
systems shall be provided by a multi-tiered multi-tiered ground response
ground support response plan. plan for ground control
systems?
B 10. A process shall be in place for assessing What process is used to Evidence of assessments.
ground to be secure. assess if ground is secure?
B 11. No person shall go beyond the area of How is this rule Evidence of rules, checks,
secure ground. communicated? Is compliance SOP’s
with this rule checked?
B 12. Systematic collection and analysis of data What type of data is collected? Evidence of data collection and
shall be in place for the management of recommendations based on
prevailing and predicted conditions and to assist How is the data used to assessments.
with pre-empting changes to the physical manage prevailing and
conditions. predicted conditions?
Page 19 of 72
Gap
E C
B 13. Systematic and ongoing monitoring shall List types of monitoring. Results of monitoring system. Observation of monitors and
be in place that assesses the implementation and discussion with personnel
effectiveness of the ground support system. How are the results assessed Recommendations based on
to measure the effectiveness of results.
the ground support system?
B 14. Documented procedures shall be in place Evidence of procedures

to ensure the safe and effective installation and
removal of ground support.
B 15. A documented risk assessment shall be Are comprehensive risk Evidence of risk assessment
conducted before any remedial work is carried assessments performed? Are
out to improve or regain stability, and appropriate reduction and control
risk reduction measures adopted. measures used to reduce the
risk to as low as reasonably
practicable (ALARP)?
C 16. The Senior Site Executive shall authorise Has the current version of the Current version of ground
the ground control plan and is accountable for its ground control plan been control plan
implementation and ongoing effectiveness. reviewed and signed off by the
Senior Site Executive?
C 17. Roles and responsibilities shall be Are roles and responsibilities Position descriptions
assigned to ensure implementation and for the ground control plan
management of the ground control plan. defined and included in
position descriptions?
Page 20 of 72
Gap
E C
C 18. A competency based training program Are competency-based List of ground support
shall be in place including, but not be limited to modules in place that includes procedures and competency
the following criteria: these listed criteria? based training modules.
· support design principles;
· the ground control plan How often is refresher training Training register
· placement and removal of supports; undertaken.
· recognition of indicators of change that may
affect ground stability; and
· ‘On the job’ training and assessment.
C 19. Suitably qualified, competent and How are these requirements Selection criteria, job
experienced person(s) shall be involved in the met? specification.
design, planning and implementation of the What criteria are used to select
ground control plan. suitable personnel?
C 20. A process shall be developed and What communication process Discussion with teams
maintained for the ongoing communication is in place and how is effective
between the geotechnical team, operations communication between these
management and operators. teams achieved?
C 21. Shift change procedures shall include Is this requirement included in Shift change over procedure. Observation and discussion
requirement to notify relevant personnel of shift change over procedures? with personnel
changes to ground control.
C 22. Behaviour based observations shall Are items related to ground Observation checklist Discuss with observers to
include work and tasks associated with ground control included in observation check understanding.
control systems. Any need for additional specific checklists? Observation analysis reports
retraining should incorporate the results of these and follow-up Check quality of observations
observations.
Page 21 of 72
FATAL RISK CONTROL PROTOCOL 5. HAZARDOUS MATERIALS MANAGEMENT SELF-ASSESSMENT
Intent: To eliminate or minimise the risk of fatalities, injuries and incidents arising from the storage, handling, production, transport, recycling and disposal of hazardous materials.
Gap
E C
A 1. The basis of design of the facility shall be Are HAZOP or similar studies HAZOP / hazard analysis
reviewed, amended as necessary and used to review facility design? study.
documented utilising HAZOP studies and hazard
analysis processes. As-built design drawings When was the last study Recommendations from study.
(e.g. process & instrumentation diagrams, undertaken?
process flow diagrams, layout drawings,
isometrics) shall be updated as a result of these
reviews.
A 2. Design specifications for all new or modified Are all identified actions arising Completed actions from Observation of controls
hazardous material facilities shall be subject to from the study complete? recommendations E.g.
risk assessment and shall detail hazardous Updated drawings, process
materials selection, storage, loading and What system is used to ensure diagrams, etc.
unloading facilities, leading industry practices, all risks are assessed when the
applicable regulations, and learnings from facility or process is modified? Evidence of comprehensive
previous incidents to ensure risk is as low as Is the hierarchy of controls risk assessment and identified
reasonably practicable (ALARP). used to achieve as low as controls
reasonably practicable
(ALARP)
% competency checks of
personnel identifying
insufficient knowledge of
hazardous materials.
How are the lessons learned

from previous incidents
assessed and implemented?
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A 3. All hazardous materials facilities shall Does the site emergency Emergency response plan Observations of emergency
provide for response to credible hazardous response plan include response equipment.
materials emergencies including the provision for comprehensive measures to
safe refuge for personnel and emergency be taken in an emergency
response equipment for spillage containment, involving hazardous material?
fires, explosions, burns, etc. and recovery and
disposal of the hazardous material.
A 4. Provisions shall be made for safe venting Is the site hazardous material Current hazardous materials Clean up / spill response kits.
and drainage, where required by normal manifest up to date and manifest
operation, emergency situations, HAZOP assessable to external
analyses or risk management. emergency services? Emergency response plan.
Evidence of risk assessment/
Does the emergency response risk management document
plan address the cleanup of
large spills/releases?
Have provisions been made for

the safe dispersal/disposal of
hazardous material?
A 5. Labelling shall be in place on all storage Has a review to determine Results of review Observations of plant
vessels, containers and tanks, as per appropriate labelling requirements as per
national or international standards. This labelling relevant standard and local
shall clearly identify the carried or stored material. legislative requirements been
Supporting information e.g. material safety data conducted?
sheets (MSDS) shall also be readily available at
the point of use and storage to identify
appropriate first aid procedures.
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A 6. Piping should be marked such that the Are up to date MSDS’s Up to date MSDS register. Observation
contents of the piping can be identified. available to personnel across
the site. SOP’s/ JSA’s Observation
Are MSDS’s available in the Current schematic diagrams of Observation of availability and
location where the hazardous piping. location of MSDS’s
material is present Observation
Do Standard Operating
Procedures and Job Safety
Assessments include MSDS’s
for hazardous materials that
may be present near the task
location.
Is all piping clearly labelled?
A 7. Security and access control systems and Are risk assessments Evidence of risk assessments Observation of physical
hardware shall be in place, appropriate to the performed to determine access barriers/ security measures.
risk, to manage access to areas where requirements for areas where
hazardous materials are stored and used. hazardous material are stored
and used?
A 8. Control systems shall ensure that the Does the system to control Risk Register Observation of controls and
potential for personnel to be exposed to hazardous materials ensure discussion with operators
hazardous materials is removed wherever that potential exposures are
possible or, where this is not possible, the removed or reduced to
associated risk is reduced to ALARP. ALARP?
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A 9. Automatic plant control systems should be Where automatic control is not Evidence of risk assessments Observations of automatic
in place to eliminate the need for operator practicable was risk failsafe equipment and
intervention to maintain operation within the assessment used to remove or Record/register of control discussions with process
design envelope. Such systems shall incorporate reduce the risk to ALARP? systems tests operators.
fail to safe systems in the event of emergencies.
What percentage of hazardous
material process is controlled
by automatic systems that
incorporate failsafe systems?
A 10. Fixed and personal detection devices shall Are fixed and personal Observation of detection
be considered as options in selection of potential detection devices used for risk devices.
risk reduction. These are the redesign and reduction?
separation controls, and personal protective
equipment as described in the hierarchy of What types of detection
controls (refer 11 below). devices are in use?
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B 11. Management of risk associated with Is the hierarchy of control Evidence of risk assessments Observation of application of
hazardous materials shall be supported by a incorporated in a documented hierarchy of controls.
documented process that incorporates risk risk reduction process?
reduction using the hierarchy of controls, applied
in the following order (a number of these options How have these controls been
may be considered and applied individually, or in applied to reduce risk
combination): (examples)?
· Elimination – the complete elimination of the
hazard;
· Substitution – replacing the material or process
with a less hazardous one;
· Redesign – redesign the equipment or work
process;
· Separate – isolating the hazard by guarding or
enclosing it;
· Administrative controls – providing controls such
as training, procedures, etc.;
· Personal protective equipment – use properly
fitted PPE where other controls are not practical;
impact minimisation equipment such as spill
clean up or dust suppression measures.
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B 12. A risk assessment process shall be in Has a risk assessment been Evidence of risk assessments
place for all hazardous materials to identify: performed on all hazardous
· The level of risk associated with the hazardous materials stored or used on Hazardous materials manifest
materials; site?
· Controls required to manage the risk to levels
that are ALARP; and
· The performance requirements (reliabilities and
capacities) of specific equipment and systems
included in these controls.
B 13. A system shall be in place to identify and Risk Register

document maintenance, inspection and testing
schedules for critical equipment associated with Maintenance plans
hazardous materials.
Inspections procedure /
schedule.
B 14. A system shall be in place whereby the What system/procedure Documented procedure Field observations and
introduction and disposal of hazardous materials controls the introduction and discussion with contractors.
must be sanctioned and approved by the site disposal of hazardous
Hazardous Materials Coordinator (Refer 29 materials?
below) prior to introduction or disposal.
Does this system also apply to
contractors?
B 15. A system shall be in place for the Change management

management of change of equipment and/or procedure
processes for handling, storage, and
transportation, and shall include specific steps to Evidence of risk assessment
assess the impact of changes on the risk
associated with hazardous materials.
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B 16. A site register shall be in place for all Does the site have current Register of Hazardous
hazardous materials, (including name, register of hazardous materials Materials
HAZCHEM code, Material Safety Data Sheets with the required information /
(MSDS), summary of maximum inventory, subject headings? MSDS
location, physical properties of the materials
where they are used, and approved disposal How often is the register Register/ Manifest
methods). The inventory movement of hazardous reviewed and updated?
materials should be controlled by means of a
register or manifest. Are current (less than 5 years
old) MSDS sheets available for
all hazardous materials stored /
used on site?
Is the transport / movement of

hazardous materials controlled
and recorded in a register or
manifest?
B 17. A system shall be in place to ensure that What system is used to ensure Documented MSDS system Location and ease of access to
MSDS are available to all personnel (including that current (less than 5 years MSDS’s
first aiders and medical personnel) involved in the old) Material Safety Data
storage, handling and disposal of hazardous Sheets are readily available to
materials on site. all personnel for all hazardous
materials used/stored on site?
B 18. A system shall be in place to ensure that How has this been achieved? Documented system
all relevant design documents and drawings,
associated with this Protocol, are up to date,
controlled and available to relevant personnel.
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B 19. Critical activities involving hazardous Are all identified critical Risk Register SOP’s and JSA’s Observation of chemical
materials shall be identified and safe-operating activities covered by standard storage / separation and
procedures documented, including storage of operating procedures or job discussion with personnel.
incompatible hazardous materials. safety analysis?
Are the storage requirements

of hazardous materials
assessed?
B 20. Safe operating limits for plant and How is this achieved? Are risk Risk assessments, Standard Observations of plant and
equipment handling hazardous materials shall be assessments undertaken to Operating Procedures equipment
clearly defined, documented and available to ensure equipment handling
operations and maintenance personnel. The hazardous material operates
limits should be marked on equipment. within recommended
manufactures specifications.
Are these limits posted/marked

on plant and equipment?
B 21. Monitoring systems for hazardous List the monitoring systems in Procedures, inspections, Evidence of
materials shall be in place to ensure that the place. training records and process inspections/audits/checks/calib
status of operation is understood and shown records. rations
clearly at all times. These systems shall include Is the status of the operation
the procedure for a documented hand-over clearly shown? Handover procedure Sign off reports by next shift
between shifts that records any relevant
information/changes in operating status. Is there a formal shift handover
system?
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B 22. A Permit to Work system shall be in place Are all of these requirements Permit to work system Observation and discussion
to ensure proper decontamination of plant and included/covered in the site with personnel.
equipment, isolation, use of the correct personal permit to work system?
protective equipment, and any special
requirements or precautions (eg. requirements for
venting or when using naked flames) where the
occupational exposure limit of a hazardous
substance could be exceeded. The application of
the permit to work process shall be used in the
planning, preparation, and execution of all tasks
where the exposure of personnel during
operation, maintenance or inspection activities is
a hazard.
B 23. A system shall be in place to control How is this achieved? View documented systems / Observation of controls and
simultaneous operations involving hazardous procedures discussion with operators.
materials to avoid mixing of incompatible Are these controls fail safe?
materials
B 24. Emergency response plans for hazardous Are hazardous material Emergency response plan Observation of muster points,
materials related incidents shall be in place and scenarios included in the alarms, evacuation plans,
annual simulation exercises shall be conducted emergency response plan Desktop scenarios exits.
as a minimum. based on the hazardous
materials used/stored on site? Documented review of last Discussion with personnel.
emergency exercise
How often are exercises held?
When was the last exercise

held?
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B 25. A system shall be in place to control and Is a system that includes all of Documented system Barriers, warning signs, etc.
monitor access to areas where hazardous these requirements in place to
materials are stored and handled. This shall also control the access to and
identify specific areas where hazardous materials security of, hazardous
may be released under certain operational materials?
circumstances (e.g. vent opening during process
upset, infrequent discharge points), and what How often is this system
restrictions are placed on access to those areas. reviewed?
B 26. A system shall be in place to authorise and Is a competency based training Training records Observation of emergency
control the training of appropriate personnel in system in place? equipment
normal handling of emergency response Results of needs analysis
procedures for hazardous materials. Has a training needs analysis
based on the hazardous
materials used on site been
conducted?
B 27. A system shall be in place to monitor short Is a monitoring program Results assessment and Observation of site monitoring
and long-term exposure to hazardous materials. utilizing both static and recommendation from equipment.
This system shall ensure that fatality potential is personal monitors in place? monitoring program.
also addressed.
Are the monitoring results
assessed?
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C 28. A site Hazardous Materials Coordinator Has a qualified Hazardous Job description Discussion with Hazardous
shall be appointed at sites where hazardous Materials Coordinator been Materials Coordinator.
materials are processed stored and handled. appointed? Are sufficient
This person shall have training and be competent resources allocated to the
to understand and evaluate the risks associated position?
with a wide variety of substances, and be able to
identify where additional expert advice can be Does the Coordinator provide a
sourced. The individual shall be responsible for site wide service/advice?
assessing the hazardous properties, and disposal
requirements of materials used, monitoring the
consumption and management of inventory, and
would also provide an “as needed” service to
supply, warehousing, operational and HSEC
personnel.
C 29. A competency based training system shall Is a competency based training Training records
be in place for operation and maintenance roles system in place?
involving hazardous materials. Use should be Results of needs analysis
made of supplier expertise to supply this training Has a training needs analysis
with annual refresher courses if required. based on the hazardous
materials used on site been
conducted?
Are suppliers required to

supply training and refresher
course?
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C 30. Behaviour based observations shall Are items related to hazardous Observation checklist Discuss with observers to
include the operation of equipment and systems materials included in check understanding.
handling hazardous materials. Any needs for observation checklists? Observation analysis reports
additional specific retraining shall incorporate the and follow-up Check quality of observations
results of these observations.
Page 33 of 72
FATAL RISK CONTROL PROTOCOL 6. MOLTEN MATERIALS MANAGEMENT SELF-ASSESSMENT
Intent: To eliminate or minimise the risk of fatalities, injuries and incidents arising from the handling and processing of molten materials.
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A 1. The basis of design of the facility shall be Has the process been Risk Register
reviewed, amended as necessary and reviewed (inherently safe)?
documented utilising the HAZOP and hazard
analysis processes. As-built design drawings (eg. Has the equipment been
process & instrumentation diagrams, process reviewed (inherently safe)?
flow diagrams, layout drawings, isometrics) shall
be updated as a result of these reviews. Have the plant logistics been
reviewed for inherent safety?
Have action plans been

document in the risk register?
A 2. Design specifications for all new or modified Has change management Change management Learnings from previous
molten material facilities shall be subject to risk system been used on all new document incidents
assessment and shall detail hazardous materials or modified facilities?
selection, storage, loading and unloading Risk assessment document
facilities, leading industry practices, applicable Have all risks been identified
regulations and learnings from previous incidents. and assessed? SOP
Has SOP been updated?
A 3. All molten material facilities shall provide for Does the site’s emergency Procedures for: Audit that equipment in
response to credible emergencies involving response plan cater for · safe refuge· emergency procedures comply with
molten materials, including the provision for safe emergencies related to hot response equipment & procedure
refuge and emergency response equipment for metal and slag? simulation
spillage containment, fires, explosions, burns, etc · spillage containment Plant drawings
and recovery and disposal of the molten material Does it list all potential · recovery & containment
possibilities?
Is the plan displayed, trained

and practiced?
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A 4. Alterations to the layout, risk control and Does the facility have an Change Management Inspect last changes to ensure
mitigation equipment and systems shall be implemented Change Procedure that controls listed in risk
covered by the change management procedures. management procedure? register were implemented
Risk Register
Does the risk register include
the risks identified during the
assessment triggered by the
last change?
A 5. Equipment associated with the handling Is identified fail-safe equipment Fail-safe equipment list Actioned.
and processing of molten materials shall be operational and tested?
designed to ‘fail safe’ in the event of power Maintenance plans Functioning
failures, power dips and surges.
Evidence of checks
A 6. Automatic plant shutdown systems (local Is there a failsafe or automatic SOP Are periodic checks done?
and remote to the hazard) shall be in place to shutdown system in place?
eliminate the need for operator intervention to Training document. Are periodic checks done?
maintain operation within the design envelope. Are people familiar with the
system?
A 7. Transport roads and rail systems for molten Are haulage roads identified Site layout Demarcation
metal carriers should, wherever possible, be and dedicated?
dedicated for this purpose and clearly Risk register with critical risks Identification signs
demarcated. Where this is not possible, risk Are the risks identified?
analysis shall be undertaken to identify the Induction Route maps
additional controls required to manage the Are the risks communicated?
activities and potential conditions in the event of a Training records Licences
molten material spillage, or loss of vehicle control Is specialised driver training
and other hazards associated with transport over undertaken? Procedures
non-dedicated routes.
Training records
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A 8. Molten materials processing and handling Is there a layout drawing of the Layout drawing Inspect Emergency Exits
areas shall have sufficient emergency exits to emergency exits available?
provide at least two means of egress from any Emergency Procedure
point. Is the access to the doors /
stairs unrestricted?
Are emergency exits clearly

demarcated?
Do emergency exit doors open

to the outside?
A 9. Water supplies to molten material areas Is water supplied to molten Risk assessment
shall be limited to dedicated systems (eg. jacket metal areas limited to
cooling) and free access to water tapping points dedicated systems?
eliminated, as far as practicable.
Is free water supply tapping
point access eliminated as far
as practically possible?
A 10. The tapping and casting processes should, Has a risk analysis been done Risk assessment Physical inspection.
wherever possible, be mechanised, automated on the tapping and casting
and controlled from a remote location. Where this process? SOP
is not possible, the alternate or additional controls
required shall be determined by risk analysis. Is the tapping and casting
process automated?
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A 11. Restricted areas for handling and Are all hot metal areas defined Site plans and procedures Demarcation and physical
processing of molten materials shall be defined and demarcated? barriers
and demarcated, and compliance managed using Access control procedure
a system of access controls. Where this is not What access control systems Signage about restricted
possible, risk analysis shall be undertaken to are in place? Induction training records access
identify the additional controls required.
Is training conducted on Audit results and compliance
restricted access?
A 12. Restricted areas and areas directly Has a risk assessment been Look at physical barriers in
exposed to molten materials processing and performed to all restricted and processing areas.
handling risk shall be safeguarded to prevent directly exposed areas where
personnel coming into contact with molten molten materials are
material or hot surfaces. Risk analysis should be processed?
undertaken to identify any additional controls
required.
A 13. All surfaces in contact with molten SOP

materials shall be coated, prepared or of such a
nature or grade that no exothermic reaction will Procedures
occur when in contact with the molten material.
A 14. Molten materials processing and handling Is there a designated area for
areas shall be designed to contain or direct any handling molten material?
spillage that may occur, and provide for safe
clean up and disposal. Are there sufficient barriers to
contain spillages?
A 15. Molten materials processing and handling Provide a list of molten Environmental and HSEC Drawings
areas will have general ventilation services, fume materials handling areas measurements
extraction facilities and emergency venting checked against Physical equipment audits
systems to minimise the exposure of people to 1. General Threshold values
dust, fumes and gases. 2. Extraction facilities PPE compliance
3. Emergency venting Health monitoring
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B 16. All molten materials processing and Has a risk assessment been Ask for procedure of risk Evaluate if controls
handling shall be subject to risk assessment. performed of all activities assessment recommended by Risk
relating to molten material Assessment were
processing and handling? Evaluate Risk Register. implemented
B 17. Procedures shall be in place for all molten SOP
materials processing, handling and safe disposal
activities. Safe Task Observations
B 18. A system shall be in place to ensure that Where are the process Drawing file/index
all process drawings are current, and are easily drawings?
accessible to operations personnel. Copy of updated drawing
Have there been any recent
equipment or process SOP
changes?
Are people aware of

equipment/process changes?
B 19. Monitoring systems shall be in place to List the monitoring systems in Procedures, inspections, Evidence of
ensure that the status of operation is shown place. training records and process inspections/audits/checks/calib
clearly at all times. These systems shall include records rations
the procedure for a documented hand-over Do they clearly show the status
between shifts that records any relevant of the operation? Handover procedure Documentation
information/changes in operating status.
Is there a formal shift handover Sign off on reports by next shift
system?
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B 20. The safe operating envelope for molten Proof definition of safe Operational Procedures eg. Check procedures versus
materials will be defined and understood by all operating envelope. temperatures and flows practices
process personnel. This shall include the
indictors (physical or systems or observation-
based) that demonstrate that the limits of safe
operation are being approached or have been
breached (eg. indicators of moisture present in
systems containing molten metal).
B 21. Critical equipment shall be defined, and Risk Register

maintenance plans for that equipment shall be
documented. Maintenance plans
Inspections
B 22. Emergency response plans shall be in Is there an emergency Copy of plan(s)
place, and annual simulation exercises shall be response plan?
conducted as a minimum. Specialist first aid and Documented date
pre-hospitalisation trauma care for injuries shall When was your last
be a component of the emergency response emergency exercise Training records
services and shall be tested during simulation conducted?
exercises.
Explain your emergency
procedure.
B 23. A procedure shall be in place to provide a Are sources of recycled Quality procedure with regards Compliance
quarantined store for alloys and other material to materials listed? to every material
be recycled into systems containing molten Physical storage
materials so as to prevent explosions, Does storage and equipment
contamination or other uncontrolled reactions. relate to risks?
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B 24. A procedure that carries the approval of Has approval of local traffic Traffic Plan Check procedure versus
the local traffic authorities, shall be in place for authorities been obtained? practice
the trackless vehicle transportation (other than Authorisation letter
rail) of any molten materials along, or crossing
public roads, over railway level crossings and
past, or through, residential areas.
B 25. The management of change process for Change management
any operation shall include specific steps to procedure
associated with molten materials. Risk analysis
Tools (eg. ICAM)

C 26. The roles and responsibilities for molten Are your people trained to SOP
materials processing and handling shall be understand the roles and
defined and assigned. responsibilities of molten Training
materials handling.
Criterion tests
C 27. A competency based training system shall Is a competency based training List of molten materials, Assessments
be implemented for operation and maintenance system in place procedures and competency
roles involving molten materials processing and based training modules
handling.
C 28. All personnel shall be trained in their Are there any emergency Emergency Procedure Check content with some
duties and responsibilities under emergency procedures? employees
conditions. Training Plan
Have all personnel been
trained in emergency Training Records
conditions?
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C 29. All personnel shall be trained on the Training records
potential acute health effects of their working
conditions and the materials handled. Minutes of tool box talks
Training modules
C 30. The use of effective personal protective Do you have PPE audits? PPE compliance document
equipment shall be monitored and enforced in all
areas where this type of control is required. How often are PPE audits SOP
conducted?
Are people aware of the

different PPE requirements for
designated areas?
C 31. A fit-for- work policy shall be in place, Does a job specification Job specification
incorporating defined action levels for drug and contain fitness requirement
alcohol and fatigue management plan. exist for all jobs related to Selection procedure
molten materials?
Does personnel selection

include a fitness for work
requirement?
C 32. Behaviour based observations shall Does observation checklist Observation Checklist Discuss with observers to
include the operation of equipment and systems include items related to molten check understanding
handling molten materials. Any need for material handling and Observation analysis reports
additional specific retraining should incorporate operation of equipment? and follow-up Check quality of observations
the results of these observations.
Page 41 of 72
FATAL RISK CONTROL PROTOCOL 7. EQUIPMENT SAFEGUARDING SELF-ASSESSMENT
Intent: To eliminate or minimise the risk of fatalities, injuries and incidents arising from hazards associated with contact with plant and equipment.
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A 1. Equipment shall be designed to eliminate How is this achieved? Evidence of risk assessments Observation of plant and
the need for guarding where practicable. and engineering reviews equipment.
Safeguarding should be selected where other Are risk assessments
potential mitigation measures do not adequately conducted and the hierarchy of
protect personnel as identified in the risk controls applied to eliminate or
assessment. reduce identified hazards to as
low as reasonably practicable
(ALARP)?
A 2. Equipment safeguards shall be designed Has a review of relevant Legislation and codes of Observation of plant and
and constructed to comply with legislation, codes legislation and codes of practice. equipment guarding and
of practice and relevant recognised leading practice been conducted to implementation of
industry practices. assess the compliance of safe Recommendations from review recommendations.
guards?
A 3. The integrity of plant and equipment Is there an inspection and Maintenance and inspection
safeguarding measures shall be continually maintenance plan for plant and plans/schedule
maintained and monitored. equipment safeguarding?
A 4. Risk assessments shall be undertaken to Have risk assessments been Evidence of risk assessments Observation of interlock
identify any safeguarded hazards that require performed on all plant and controls.
interlock systems as an additional control. equipment to identify the need
for interlock controls?
A 5. Access to equipment shall be controlled and Is a system in place to control Documented system Barriers, warning signs, etc.
monitored where safeguarding and interlock access to moving plant and
systems are insufficient to protect persons from equipment?
moving plant and equipment.
How often is this system
reviewed?
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A 6. Fail to safe switches or devices shall be Are fail to safe switches Equipment register Observation of rotating
installed on all rotating fixed plant and hand tools installed on all rotating fixed equipment and hand tools
(eg. saws, lathes, drill presses, etc). plant and hand tools?
Is a register kept of all

equipment requiring fail to safe
switches
A 7. Guards shall only be removed for Are these requirements Permit to work system Observation and discussion
maintenance and repair, and only once included in the site permit to with site personnel
equipment is isolated and locked out. Guards work system?
shall be replaced prior to equipment being put
back into service.
B 8. A risk based process shall be used to How has this been achieved? Recommendations from review Observations of plant and
identify all possible areas where safeguarding is equipment.
required
B 9. All documentation related to the risk Does the site have a document Document control system
assessment and selection of the safeguarding of control system?
equipment required shall be retained and
controlled.
B 10. Procedures shall be in place for situations Is this requirement Permit to work system Observation and discussion
when safeguards on operating plant and included/covered in the site with personnel
equipment needs to be removed temporarily for permit to work system?
any purpose.
B 11. A system shall be in place for the Does the site have a formal Change management
management of change to equipment and/or change management document
processes to ensure the integrity of safeguarding procedure that is applied to
is maintained and to determine requirements for plant and equipment?
additional safeguarding.
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B 12. No guarding shall be modified or altered in Change management Site observations
any way except through the application of a document
detailed risk assessment and change
management process. Evidence of risk assessment
C 13. A competency based training system shall Is a competency based training Training records
be in place for operations and maintenance that system in place? Results of needs analysis
includes the requirements of this Protocol.
Has a training needs analysis
for plant and equipment been
conducted?
C 14. Behaviour based observations shall Are items related to plant and Observation checklist Observation analysis reports
include work activities associated with equipment equipment included in and follow-up
safeguarding. Any need for additional specific observation checklists? Observation analysis reports
observations.
Page 44 of 72
FATAL RISK CONTROL PROTOCOL 8. ISOLATION SELF-ASSESSMENT
Intent: To eliminate or minimise the risk of fatalities, injuries and incidents arising from the uncontrolled release of energy or hazardous materials.
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A 1. Purchase and design of equipment shall How is this achieved?
give due consideration to meeting the
requirements of this Protocol.
A 2. Isolation shall provide positive protection Does the site have Isolation procedure
and be achieved by the use of locking devices or comprehensive isolation
establishment of a physical barrier or separation. procedure?
All separations or physical barriers shall be
provided with either a permanent or temporarily
fitted locking device whenever possible.
A 3. Personal locking devices shall: Do personal locking devices Observations and discussions
· Be uniquely keyed; meet these requirements? with personnel and contractors
· Not be combination locks;
· Not have an unauthorized second-party master Are personal locking devices
override key; and issued to all site personnel,
· Be kept under the exclusive control of the including contractors?
owning individual, and key(s) shall not be
transferred to another person for lock removal.
A 4. Designated isolation points shall be clearly Have all isolation points been Isolation procedure Observation of isolation points
labelled to identify the circuit or system over identified for all energy sources
which they have direct control. These labels shall and equipment?
be applied by following a process of pre-isolation
identification using isolation lists, marked Are all designated isolation
drawings etc. (where permanently applied these points clearly labelled?
shall be physically verified prior to the isolation).
What procedure is followed for
pre- isolation identification?
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A 5. Lockout boxes, stations or equivalent shall Is the use of this equipment View procedure Observation of group isolation
be provided where required. included in the site isolation
procedure?
Is this equipment readily

available?
A 6. All hired and contracted equipment shall be How is this achieved? Observation of hire equipment
reviewed to ensure it meets site isolation
requirements and the requirements of this
Protocol, before use on the site.
A 7. All designated isolation points fitted with Does the site isolation tagging Isolation tagging procedure Observation of tags
personal locking devices shall be tagged. The system meet these
isolation tagging system shall ensure that: requirements?
· Isolation points are positively identified;
· The reason for the isolation is clearly identified;
and
· Isolation tags are highly visible to prevent
inadvertent operation.
B 8. All sites shall have a documented isolation Isolation/Tag-out procedure

and lock out/tag out system.
B 9. The isolation system shall be applied to all How is this achieved? Isolation procedure Observation and Discussion
activities on site, including contractor activities with personnel and contractors
(ie. construction, commissioning, operation,
maintenance, return to service, emergency,
modification or demolition of equipment).
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B 10. An additional overall isolation and lock out Are isolation guidelines in Isolation guideline
guideline shall be in place, and include definitions places that include these
of appropriate treatment for routine isolations, requirements?
group, master and /or multiple isolations, short
term isolations and long term isolations
(‘mothballing’ procedures are only required prior
to such activity.
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B 11. The isolation guideline should use a risk- Are risk assessments to Isolation guideline
based process to determine the appropriate determine appropriate isolation
isolation method for any activity (either by way of methods specified in the
a full description for specific cases, or by isolation guidelines?
demonstrating the process that shall be followed
to achieve the appropriate level of isolation in
new activities). This should include, but not be
limited to:
· the role of work instructions, checklists, and the
Permit to Work system;
· a positive registration process for people
working on isolated equipment (personal tag, log
sheet, etc.);
· changed requirements associated with the
duration of the isolation and task(s), or when
tasks take longer than planned to complete;
· energy sources to be isolated (hazardous
materials, mechanical, electrical etc.);
· the physical state of the energy sources such as
their phase (liquid, solid, vapour, etc.) and other
characteristics (eg. Pressure, voltage etc.);
· controls required for the duration of the activity
(temporary engineering and operating changes,
emergency procedures, personal protective
equipment etc.);
· the requirements for formal contact with
representatives in charge of each facility area
affected, and the process for granting written
B 12. A procedure shall be in place for transfer Is there a formal procedure View hand over/ hand back
(hand over) and return (hand back) of control that covers hand over / hand procedure
over the plant or equipment between operations back?
and maintenance teams.
Page 48 of 72
Gap
E C
B 13. A system of formal documented Is there a formal procedure Completed clearance
‘clearances’ for work to proceed following that covers this requirement? documents
isolation and de-isolation shall be in place.
B 14. Documented system-specific isolation Are surveys undertaken to List of critical equipment and Observations
procedures shall be in place for critical equipment identify critical equipment and isolation procedures
(such as critical alarms, emergency shutdown procedures developed for the
devices, relief and blow-down valves, fire and gas isolation of this equipment?
detection and protection devices, and other items
as designated in the critical equipment register).
B 15. Specific procedures shall be developed to Are procedures in place to Soft ware override procedures
address software overrides as their functions are address software overrides?
electronically initiated and applied to control
rather than power circuits.
B 16. Documented test procedures shall be Are these requirements View procedure Observation and discussion
provided to verify isolation integrity including, but included in the isolation with personnel
not limited to the following principles: procedure?
· identification of all energy sources or hazardous
materials directly and indirectly relating to the How are all sources of energy
work to be performed; identified when multiple
· confirmation of those systems requiring isolation is required?
isolation;
· isolating the confirmed energy or hazardous How is an energy free state for
material sources; isolated equipment confirmed?
· application of lock/tag;
· application of isolation tag; and
· trying/testing of all systems and non-redundant
isolations when reasonably or feasibly possible
(to verify the integrity of the isolation and ensure
a zero energy state exists.)
Page 49 of 72
Gap
E C
B 17. A procedure shall be in place to mitigate Does the site have a procedure Procedure
hazards in cases where any one of the following that addresses these listed
is not achievable: requirements?
· a zero energy state;
· a test/try of non-redundant means of isolation;
or
· use of a locking device is not feasible.
B 18. Formal isolation procedures shall include Is the removal of personal Incident investigations Discussion with personnel
requirements for investigation, reporting and locks/tags by other than the
removal of personal locks/tags by an authorised originator fully investigated?
person other than the originator.
B 19. A system shall be in place for the Does the site have a formal Change management
management of change of equipment and/or change management document
processes for the isolation system, or installed procedure that is applied to the
isolations, and shall include specific steps to isolation system?
associated with these changes. This system
shall include, but not be limited to:
· changes to process conditions;
· purchase of new equipment;
· modifications to existing equipment;
· internal and external incident findings and
learnings; and
· the need for revision of the System and/or
Guideline and/or additional training.
B 20. The Isolation system shall be regularly How often is the system Recommendations from last
reviewed to capture any previously un-identified reviewed? review
changes, and revised when necessary.
When was the system last
reviewed?
Page 50 of 72
Gap
E C
C 21. Site role(s) for individuals with Are these responsibilities Position Descriptions Discussion with personnel
responsibility for electrical, mechanical, or included in Position
process isolation management shall be defined. Descriptions?
C 22. A competency based training system and Is a competency based training Training records
field assessment shall be in place to approve system in place?
personnel before they conduct isolation Results of needs analysis
processes. Has a training needs analysis
for plant and equipment been
conducted?
C 23. Behaviour based observations shall Are items related to isolation / Observation checklist Discuss with observers to
include tasks and activities associated with tag out included in observation check understanding.
isolation. Any need for additional specific checklists? Observation analysis reports
observations.
Page 51 of 72
FATAL RISK CONTROL PROTOCOL 9. WORKING AT HEIGHTS SELF-ASSESSMENT
Intent: To eliminate or minimise the risk of fatalities, injuries and incidents arising from working at heights.
Site: Enter Site Name Here z Completed/Approved By: Insert Name Here
Gap
E C
A 1. All working at height equipment shall What working at height List of applicable standards
comply with relevant approved design standards. standards and legislation apply and legislation
at this site.
Has compliance to these

standards been assessed?
A 2. Single person anchor points shall be Is there a program of testing Test results Observation of anchor points
capable of withstanding 15kN (approximately single person anchor points to
3,372 lbf). ensure they meet these
requirements?
A 3. Where personnel are required to work Are these requirements SOP’s and JSA’s Observation of lanyards and
within 2 metres of an opening where they could contained in standard harnesses
fall, they shall use personal fall restraint operating procedures? Evidence of assessments
equipment, such as a fixed lanyard and harness
as a minimum, which will prevent them from Are assessments conducted to Register
falling over the edge. determine if this requirement
applies?
Is there a register of
areas/tasks where personal fall
restraint equipment must be
worn?
Page 52 of 72
Gap
E C
A 4. Where there is potential to fall more than 2 Has all work where this fall Working at heights register. Observations and discussions
metres, personnel shall wear appropriate potential exists been with personnel
personal fall arrest equipment. In such identified? Document working at heights
circumstances a full body harnesses, including Permit Observation of equipment
shock-absorbing lanyard is mandatory. The use How is compliance with these
of body belts for fall arrest is prohibited, except requirements achieved?
for specialised tasks such as pole-climbing belts
worn by specially trained linesmen. Are these requirements stated
in the site working at heights
permit system?
Is this equipment maintained

and available?
A 5. All forms of portable and movable elevated Are portable elevated work List of relevant standards and Observation of equipment and
work platforms and suspended work cages shall platforms assessed to ensure date of last assessment. discussion with personnel
conform to relevant approved design standards. compliance to relevant
People in the work platform basket shall wear a standards? Results of checks/ audits
correctly fitted harness attached by a lanyard to a
suitable anchor point in the basket. This does not How is this requirement met?
apply to people working from a properly
constructed and certificated scaffold with the Are spot checks/audits
requisite handrails and toe boards) conducted to ensure
compliance?
Page 53 of 72
Gap
E C
B 6. The need to work where there is the risk of Where a risk of fall is identified Evidence of risk assessments
a fall shall be eliminated where reasonably are risk assessments
practicable. Personal fall arrest equipment shall conducted and the hierarchy or
be used only when all other control measures controls applied to eliminate or
have been explored and deemed to be not reduce the hazard to as low as
reasonably practicable. reasonably practicable
(ALARP)?
B 7. Standard work procedures shall be in place Standard work procedures.

for the correct wearing and use of personal fall
arrest and fall restraint equipment.
B 8. There shall be a work permit system in Is working at heights included Working at heights permit
place to control all working at heights. in the work permit procedure? procedure.
Page 54 of 72
Gap
E C
B 9. A documented risk assessment shall be Is a risk based process used to Evidence of risk assessments
conducted before the commencement of work determine appropriate controls and evaluation process.
and at any time the scope of work changes or the prior to the task commencing
risk of a fall increases. The risk assessments or if the scope of the task
shall include: changes?
· consideration for the potential of objects, as well
as personnel, to fall; Are these listed requirements
· selection of appropriate control measures using included in this process?
the hierarchy of controls
;· the possibility for weather and other
environmental conditions to influence the working
conditions (eg. wind, rain, snow, dust, gases,
poor lighting, temperature etc.);
· selection of appropriate equipment;
· selection of anchor and tie off points;
· condition of supporting structures such as roofs;
and
· fall clearances i.e. length of lanyard + tear-out
distance + height of user + safety margin.
B 10. All equipment shall be fit-for-purpose and Are all of these requirements View inspection results and Observation of equipment
undergo pre-use checks and a minimum of six- included in an inspection and equipment register
monthly (bi annual) documented inspections by a tagging system?
competent person. An equipment register and
tagging system shall be in place to indicate When as the last six monthly
compliance with this inspection. inspection?
Page 55 of 72
Gap
E C
B 11. Where the work method requires persons Is this requirement contained in SOP’s and JSA’s
to detach and re-attach at height, a dual lanyard standard operating procedures
system shall be utilised to ensure that at least and job safety analysis?
one connection point is maintained at all times.
B 12. Where the use of personal fall arrest Is this requirement Standard Operating Procedure Observation
equipment is required, a person shall not work documented in a procedure or
alone, there shall be other personnel in the permit to work system?
vicinity who can raise the alarm immediately
should a person fall. Are checks conducted to
assess compliance?
B 13. Persons working at height, shall ensure Is wearing a helmet fitted with Rules / Standard operating Observation
that their safety helmets are secured by using a a chinstrap whilst working at procedure
helmet chinstrap. height mandatory?
B 14. A system should be in place to prevent How is this achieved? Observation of preventative
tools and other objects from falling from height. measures in situ
B 15. Barricading and warning signage should Is this a requirement of the Site observation
be placed on all lower levels where personnel or working at height permit?
objects may fall.
B 16. Personnel operating elevated work Is competency based training Training records
platforms and cages shall be trained and certified provided for personnel
for the equipment they are using. operating elevated work
platforms and cages?
Are all personnel who operate

this equipment certified?
How often is refresher training

undertaken?
Page 56 of 72
Gap
E C
B 17. The site emergency response plan(s) Does the emergency response Emergency Response Plan Discussion with emergency
should include plans for the rapid retrieval of plan include fall from height response team members.
personnel in the event of a fall from height. scenarios? Emergency exercise
(Response time is critical if a person is left documentation
suspended from a harness.) Are emergency response
exercises based on fall from Training records
height scenarios held?
When was the last exercise?
Do emergency service
personnel receive specialized
training for responding to a fall
from height event?
C 18. Sites shall conduct a process to ensure Do job specifications Job specification
selected personnel to work from heights are containing fitness requirements
physically and psychologically suitable for work at exist for all jobs related to Selection procedure
height. Specific consideration shall be given to working at heights?
personnel who suffer medical conditions, such as
vertigo and epilepsy, as well as considering the Do personnel selection
weight of the person using the harness. (Note: requirements include a fitness
many harness systems have a maximum weight for work requirement
limit of 136 kg/300 lbs.)
Page 57 of 72
Gap
E C
C 19. A competency based training program for Is a competency based training Training records
employees and supervisors should be in place, system in place?
which includes provisions for maintaining Results of needs analysis
competence. All persons engaged in work How often is refresher training
defined in this Protocol shall be adequately required?
trained and assessed for competency.
C 20. Behaviour based observations shall Are items related to working at Observation checklist Discuss with observers to
include activities and tasks associated with heights included in observation check understanding.
working from heights. Any need for additional checklists? Observation analysis reports
specific retraining shall incorporate the results of and follow-up Check quality of observations
these observations.
Page 58 of 72
Raw Data for FRCP Audits from sites
Business Unit Site FRCP Item Category BHPB Contractor
Enter Business Unit Enter Site Name Her 1 1 A 0 0
Enter Business Unit Enter Site Name Her 1 9 B 0 0
Enter Business Unit Enter Site Name Her 1 17 C 0 0
Audits from sites
BHPScore Contract Score Total Comments
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
#N/A N/A N/A 0
Data
FRCP Employees Contractors Overall
1 #N/A #DIV/0! #DIV/0!
2 #N/A #DIV/0! #DIV/0!
3 #N/A #DIV/0! #DIV/0!
4 #N/A #DIV/0! #DIV/0!
5 #N/A #DIV/0! #DIV/0!
6 #N/A #DIV/0! #DIV/0!
7 #N/A #DIV/0! #DIV/0!
8 #N/A #DIV/0! #DIV/0!
9 #N/A #DIV/0! #DIV/0!
Grand Total #N/A #DIV/0! #DIV/0!
Overall Score Across Enter Site Name Here By Fatal Risk Con-
trol Protocol
100%
90%
80%
70%
60%
Compliance
Total
50%
Target
40%
30%
20%
10%
0%
1 2 3 4 5 6 7 8 9 Over
all
Fatal Risk Control Protocol

Employee/Contractor Scores Across Enter Site Name Here By
100%
90%
80%
70%
60% Employees
Compliance
Contractors
50%
Overall
Target
40%
30%
20%
10%
0%
1 2 3 4 5 6 7 8 9 Over
all

Category Scores Across Enter Site Name Here By Fatal Risk
Control Protocol
100%
90%
80%
70%
60% Plant & Equip.

Compliance
Procedures
50%
People
Target
40%
30%
20%
10%
0%
1 2 3 4 5 6 7 8 9 Over
all

FRCPSelf Assessment Template

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HSEC TOOLKIT

FATAL RISK CONTROL PROTOCOLS

Business Unit: Enter Business Unit Name Here

Instructions For Completion

1 Only the fields shaded in yellow can be edited.

A 3. Technological advances should be How is this achieved? Evidence of systems

B 14. Documented procedures shall be in place Evidence of procedures

How are the lessons learned

Have provisions been made for

Is all piping clearly labelled?

B 13. A system shall be in place to identify and Risk Register

B 15. A system shall be in place for the Change management

Is the transport / movement of

Are the storage requirements

Are these limits posted/marked

When was the last exercise

Are suppliers required to

Have action plans been

Has SOP been updated?

Is the plan displayed, trained

Are emergency exits clearly

Do emergency exit doors open

A 13. All surfaces in contact with molten SOP

Are people aware of

B 21. Critical equipment shall be defined, and Risk Register

Tools (eg. ICAM)

Are people aware of the

Does personnel selection

Is a register kept of all

Is this equipment readily

B 8. All sites shall have a documented isolation Isolation/Tag-out procedure

Has compliance to these

Is this equipment maintained

B 7. Standard work procedures shall be in place Standard work procedures.

Are all personnel who operate

How often is refresher training

When was the last exercise?

Fatal Risk Control Protocol

Fatal Risk Control Protocol

60% Plant & Equip.

Fatal Risk Control Protocol

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