OH&S Plant Obligations make Plant Maintenance OH&S Plant Obligations make Good Business Sense!

Regulations for Plant Objective for you to understand: The purpose and requirements of the Regulations for Plant (WA) and NOHSC:1010 (National) The purpose of, and requirements for, Plant Maintenance The analysis techniques for both are the same That neither are too difficult or onerous for you to do; and For completeness, both should be completed together

Regulations for Plant Peter Kohler Capability by Design Pty Ltd. Maintenance engineering (Policy and Implementation) Learning workplace programmes Business systems engineering “Regulations for Plant” specialist National Chairman (Maintenance Engineering Society of Australia)

Regulations for Plant Agenda What is OH&S and what are the “Regulations for Plant” What the “Regulations for Plant” requires of business and you What effective Plant Maintenance requires of business and you The differences in approach between the “Regulations for Plant” and effective plant maintenance How both can contribute to your competitive prosperity

Regulations for Plant In general, how would you comply with the OH&S requirements for a 400 bar high pressure air vessel? Can you comfortably sign a “Safe to Use” certificate for that pressure vessel in your business, right now?

Regulations for Plant References National Standard for Plant NOHSC:1010 (1994) OH&S Act 1996, Part Four, “Plant” (Worksafe WA) AS/NZS 3931 Risk Analysis of Technological Systems - Application Guide AS/NZS 4360 Risk Management IEC 61078 Failure Mode Effect Analysis US Military Std 882B System Safety Programme Req’ts AS/NZS 3907 Guidelines for Configuration Management

Regulations for Plant OH&S Act: Intention is to develop a demonstrably safe work environment, through: Workplace OH&S responsibility structure Requirements for Plant Designers and Verifiers Requirements for Plant Manufacturers and Installers Requirements for Plant Users (Owners) Requirements for OH&S and Owners in terms of Licensing Plant designs Permits for Use of certain types of plant.

Regulations for Plant OH&S Act requires: Designers, Installers, Owners and Operators to Determine any hazards associated with the use of the plant Undertake a “risk assessment” of the use of plant Determine any necessary risk control measures Document and provide all such above information The provision of an auditable trail of plant hazard and risk control measures decision making The “Licensing to Use” and the “Registration of Design” of certain types of plant

Regulations for Plant What is ”Plant”? WA: Items of physical equipment which, in order to work, requires the supply of energy of a kind other than, or in addition to, the energy supplied by the exertion of the body of a human or an animal. VIC: Type of plant includes any component of the plant or type of plant and anything fitted, connected or appurtenant to the plant or typo of plant NOHSC:1010 Includes any machinery, equipment, appliance, implement or tool and any component or fitting thereof or accessory thereto.

Regulations for Plant - WA Persons who design plant to provide Information: A person who designs plant for use at a workplace must ensure that the person who manufactures the plant is to provide information relating to — the purpose for which the plant is designed testing or inspections to be conducted in relation to the plant systems of work necessary for the safe use of the plant the current design registration number (if any) issued by the Commissioner or by a regulatory authority for that kind of plant; and emergency procedures relating to the plant to accompany the plant when it is manufactured, supplied, installed or erected, inspected and used at a workplace.

Regulations for Plant OH&S Act Regulations require the following records to be kept: A list of the Plant in use The Designed Use of that plant The Actual Use of that plant The foreseeable hazards associated with the use of that plant The determined risk control measures Maintenance etc performed on that plant A signed “Safe to Use” certificate by the owner

List of Plant

Plant Details

Plant Regulation Requirements

Designed and Actual Use

HAZARD Analysis

Regulations for Plant How do you conduct a Risk Assessment? AS/NZS 4360 Risk Management Develop the Context of the risk assessment Probability and consequence criteria Prioritize hazards Develop risk mitigation strategies and tasks Implement Review and monitor US Military Standard 882C System Safety Program Requirements: Context of the safety system Criteria for probability and consequence Prioritize the hazards using a hazard matrix Develop risk mitigation strategies and tasks Implement Review and monitor

OH&S and Plant Maintenance But what is the cost/benefit of NOHSC:1010 to Australia? Reference: Economic Analysis on the Impact of 1010. Currently: 70,000 plant related injuries each year in Australia; and 200 fatalities each year Reduction of 24 per cent injuries would deliver: Direct savings of $1.4b over 10 years Indirect savings of $7.8b over 10 years The cost to business for the next 10 years across Australia: Hazard Identification $303M Risk Control $3,357M Training $903M Record Keeping $123M Plus all the other non monetary benefits from less injuries and trauma to individuals and families

Regulations for Plant What are the “Regulations for Plant” in: Commonwealth NOHSC:1010, since 1996 NSW “Plant Regulations” in February next year Victoria OH&S Plant Regulations, since 1995 WA Regulations for Plant, since 1996

Regulations for Plant How would you develop the necessary maintenance tasks for a 400 bar high pressure air vessel? Can you confidently demonstrate to that, as a result, the air vessel is both “Safe to Use” and efficiently delivering the required outputs for your business?

Regulations for Plant The principles of Plant Maintenance Focus is upon what assets “do” or “their use” Failure is defined in terms of what the business wants each asset to “do” Maintenance tasks are developed by understanding: What the business wants each asset to “do” The hazards associated with each asset in the delivery of what it “does” The likelihood of the occurrence of each hazard The consequences to the business of each hazard What needs to be done to reduce the likelihood and/or consequence of each hazard

Regulations for Plant Maintenance Analysis: AS 3961 Risk Analysis of Technological Systems - Application guide IEC 61078 Failure Mode Effect Analysis Risk Analysis: AS/NZS 4360 Risk Analysis

Regulations for Plant What are the differences between the approach for “The Plant Regulations” and that of Plant Maintenance? The Plant Regulations primary focus is on personal and personnel safety The focus of Plant Maintenance is both efficient and effective Plant performance and personal and personnel safety, and But that both use the same risk analysis process

Regulations for Plant As a result, you can: Use one simple, integrated, consistent and complete approach to the determination of: OH&S requirements Plant maintenance requirements Even Plant operating tasks (start, run, stop and emergency) and Plant instrumentation needs!

© Capability by Design Pty Ltd.. Plant, Operations and Maintenance © Capability by Design Pty Ltd.. Phone: 029 681 6334 Fax: 029 681 6335 Email: kohler@tpg.com.au

Regulations for Plant Smart businesses recognise that: One simple analysis approach delivers all your maintenance and Plant Regulation needs Both should be conducted at the same time to achieve an effective and a cost effective analysis process, and Only one analysis, information and compliance system is needed to demonstrate both Plant Regulation and plant maintenance compliance

The complete OH&S “Plant Regulation” and plant maintenance analysis Introducing Assure™ The complete OH&S “Plant Regulation” and plant maintenance analysis and compliance system! Currently, Assure™ complies with the following Australian and international Standards: NOHSC:1010 National Standard for Plant AS 3931 Risk Analysis of Technological Systems AS 4360 Risk Management US Military Standard 882C System Safety Management IEC 60812 Failure Mode Effect Analysis IEC 61078 Reliability Block Diagramme IEC 61025 Fault Tree Analysis.

How can Capability by Design help you? Plant Analysis and OH&S software tools using Assure™ Plant management information systems auditing and developing Plant maintenance audits Plant Management Policy Manual development Plant maintenance analysis & analysis tools tailoring Strategy Based Learning™ for developing a learning environment in the workplace Business Centred Maintenance Implementation Programme(s)