Boral Building Products - NSW Pollution Incident Response ... · Pollution Incident Response Management Plan (PIRMP) ... LPG Gas Tank Ref # 14 Cement Silos . ... • SWMS / SOP

Boral Building Products - NSW

Pollution Incident Response Management Plan (PIRMP)

Boral Montoro – Emu Plains Production Facility

Date: May 2016

Ref # 6

Dispatch Office

Ref # 1

Greases & lubricants

Gases Store

Ref # 2

Workshop

Ref # 8

QA Laboratory

Ref # 7

Administration Office

Ref # 10

Truck Loading Area

Ref # 11

Stock Yard

Ref # 5

Concrete Washout Pits

Ref # 4

Canola Oil

Ref # 3

Workshop 2

Ref # 12

Additives

Ref # 9

Dry Waste Area

Ref # 13

LPG Gas Tank

Ref # 14

Cement Silos

PIRMP Site Assessment Sheet

LIST OF POLLUTING SUBSTANCE STORAGES/USES AT SITE INITIAL ASSESSMENT

(all Chemicals listed in this sheet are to be subjected to a risk assessment)

Site Name:

Emu Plains

Responsible Person:

Warwick Juno (Plant Mngr)

Revision Dates:

1st

- 26/08/12

2nd – 02/05/13

3rd

– 05/06/14

4th

– 06/05/16

Name /

description

Covered under

Haz

Chemicals/MSDS?

Amount

stored

Location of

storage

Map

reference

Need for

early

warning1

Current controls See Risk Ass &

PIRMP Response

Action (see

Below)

CHEMICALS/FUELS/LUBRICANTS (raw materials and products which can cause pollution)

Oils/Solvents Class 3 Packaged

goods up

to 2000

Ltrs

Oil Storage Shed Ref No 1

Ref No 8

Local Fire

Brigade

• Portable Bunding

• Training

• Flammable Cabinets

• Spill Kits

• Inductions

• Fire Fighting

Equipment

• Security

• Isolated from factory

Incident # 1

Lubricants, Gases Class 2 Variable Maintenance

Workshop

Ref No 1

Ref No 2

Ref No 3

Local Fire

Brigade

• Fire Extinguishers

• Concrete Floor

• Enclosed / screens

• Containment Cages

and Cabinets

• Trained Personnel

• SWMS / SOP

• Isolated / lock up

areas

Incident # 2

MATERIALS (eg stockpiles, silos, bulk solids etc) – Vehicles used to load and move raw materials

1 Early warnings relate to informing neighbours who may be affected by the emission of this substance. If this substance is of a type and quantity which may reach

neighbours then early warning assessment of actions is required to be undertaken.

LPG Gas Class 2 Above

ground

5000 Litr

tank

Adjacent Staff

car park

Ref No 13 Local Fire

Brigade

• Fire Extinguishers /

Hydrant

• Trained Personnel

• SWMS / SOP

• Isolated / lock up

dispenser

Incident # 3

Additives

Canola Oil

Refer to Boral’s

MSDS

20,000

Ltrs

Storage Tank

opposite wash

out pits

Ref No 4 Local Fire

Brigade • Area Bunded

• Emergency fire

equipment

• Maintain

manageable levels

• Maintained delivery

equipment

Incident # 4

Additives

Oxides

Refer to Boral’s

MSDS

Max

5 tonnes

Dedicated on

site

Ref No 5 N/A • Emergency fire

equipment

• Maintain

manageable levels

• Maintained Load

shifting equipment

• Immediately clean

up spills

Incident # 4

Cement Silos Refer to Boral’s

MSDS

Max 35

Tonnes

Vertical Silos Ref No 14 N/A • Silos fitted with high

level warning and

cutout systems

• Silos fitted with

Baghouse and

overfill system

• Safety systems

regularly serviced

Incident # 5

Residue Waste N/A Variable Dedicated on

site

Ref No 9 N/A • Emergency fire

equipment for FEL

• Maintain

manageable levels –

remove excess waste

• Security

• Maintained Load

shifting equipment

Inert

No potential

incident

AQUEOUS (eg dams, wastewater tanks, other water storage area)

Concrete Wash

out pits

N/A Variable Concrete Wash

out pits

Ref No 5 N/A • Ensure wash out pits

are regularly

emptied and waste

remove from site

• Trained personnel

• Ensure pumps are

maintained through

scheduled

maintenance

• FEL maintained

• Qualified operator

Incident # 7

Yard Run off

Storm Water

Drains

N/A Variable Ref No 8 N/A • Regular inspection of

pump unit and

sediment level

• Ensure pumps are

maintained through

scheduled

maintenance

• Straw Bales

• Rubber and Earthen

Berms

• Audits

Advise Quarry

Manager if release of

water to the Quarry

dam is expected

Incident # 7

SUBSTANCES IN PROCESSES (substances which could be emitted from operational process i.e. treatment plants, vehicles etc)

Name /

description

Covered under

Haz

Chemicals/MSDS?

Amount

stored

Location of

storage

Map

reference

Need for

early

warning2

Current controls See Risk Ass &

PIRMP Response

Action (see

Below)

Mobile Plant

(onsite) BORAL

LPG Powered Up to 4

on site

Dedicated on

site

N/A N/A • Spill Kits

• Pre start checks

• PMP

• Training

Incident # 8

Mobile Plant Class 3 Variable Variable N/A N/A • Spill Kits Incident # 9

2 Early warnings relate to informing neighbours who may be affected by the emission of this substance. If this substance is of a type and quantity which may reach

neighbours then early warning assessment of actions is required to be undertaken.

Contractor/visitor Locations • Training

• Inductions

Car Parking up to

40 vehicles

Class 3 Variable Site Office Ref No 10 N/A • Spill Kits

• Training

Incident # 9

IMPACT ON NEIGHBOURS ASSESSMENT – EARLY WARNINGS Site Name: Emu Plains

Responsible Person: Warwick Juno Date: 06/04/16

Incident

type/description

External Release (air,

waterway etc)

Neighbors

impacted/extent of

impact

Communication

methods

Early warnings

Actions and other control measures (eg posting on website, community group meetings)

Cement dust discharge Air Minor Local Radio/News Follow up by Site Manager if required

Emergency Drills Conducted

Date Practice Drill

Completed

Type of Drill Rating 1-5 on

Effectiveness

Comment

24/03/2012 24/03/2012 PIRMP 5 Highly Effective Minimal Recommendations




RISK ASSESSMENT MATRIX

TABLE 1: Measures of Consequence

Value Description Impact

1 Minor On-site release immediately contained

2 Moderate On-site release immediately contained with outside assistance

3 Major Off –site release regional or national impact long term damage with specialist clean up required

TABLE 2: Measures of Likelihood

Value Description Impact

3 Highly Likely The event could occur weekly in normal circumstances.

2 Likely The event could occur once per month

1 Unlikely The event could occur once every one to five years.

TABLE 3: Risk Ranking Table

Consequence Likelihood

Minor

(1)

Moderate

(2)

Major

(3)

Highly Likely (3) M (3) H (6) H (9)

Likely (2) L (2) M (4) H (6)

Unlikely (1) L (1) L (2) M (3)

RISK ASSESSMENT on POTENTIAL IMPACTS

Hazard and Likelihood Risk Assessment and Corrective Control Measures

Emu Plains

Responsible Person Plant/HSE Managers

Review Date 6th April 2016

Name / ref of

pollutant/ chemical

Description of Hazard / Incident leading to hazard

Consequence

Likely hood

Risk

Impact on

neigh-bours

3

Control Measures Corrective Action

Coverage under other Plans

Responsible person

Action date

Oils/ Solvents

Incident # 1 Loss of oils solvents inside bund during delivery and or use

1 1 L1 N/A Consequence :(Minor): Failure resulting in loss of oils/solvents from packaged goods would be captured entirely by existing primary bund with no release to soil or water. Likelihood :(Unlikely): Due to location within the bund, spillage during

As per PIRMP

action plan

When required

3 If the incident may impact on neighbours then it will need to trigger the early warnings assessment and actions

delivery and use is unlikely to occur. In addition hoses and decanting equipment are maintained in good structural integrity with low risk of failure.

Lubricants / Gases

Incident # 2 Loss of oils / gases inside bund during delivery and or use

1 1 L1 N/A Consequence :(Minor): Failure resulting in loss of oils/solvents from packaged goods would be captured entirely by existing primary bund with no release to soil or water. Likelihood :(Unlikely): Due to location within the bund, spillage during delivery and use is unlikely to occur. In addition hoses and decanting equipment are maintained in good structural integrity with low risk of failure.

As per PIRMP

action plan

When required

Gas leak form storage tank

Incident # 3 Loss of gas and potential for fire / explosion

2 1 L2 N/A Consequence :(Minor): Failure resulting in loss of gas from tank and potential for fire / explosion. No release to soil or water. Likelihood :(Unlikely): Due to location of tank, and protective barriers, damage to tank and exposure to heat sources, likely to cause operation of relief valve are unlikely to occur. In addition hoses and decanting equipment are maintained in good structural integrity with low risk of failure.

As per PIRMP

action plan

When required

Liquid Storage Tanks

Incident #4 Catastrophic failure of one or more Canola Oil / liquid Oxide tanks releasing large volumes of liquids into on-site and off-site water courses (i.e creek).

1 2 L2 N/A Consequence: (moderate): Catastrophic failure of one or more bulk liquid storage tanks are likely to result in no off-site impacts to water courses due to on site and Boral Quarry on site retention dams. As such, impact to the environment/human health is not considered to be significant. Likelihood: (unlikely): Quarry dams are frequently monitored and inspected for levels and integrity. Risk Assessment = Moderate Vs Unlikely = L (2) Note: For PIRMP purposes overflow events during extreme wet weather will be reported under POEO Licence obligations and not Immediate Reporting.

As per PIRMP

action plan

When required

Cement Silos

Incident # 5 Release of dust to atmosphere

1 2 L2 Y Consequence :(Minor): Failure resulting in loss of cement dust gas from silo and potential for air contamination. No release to soil or water. Likelihood :(Unlikely): Due to location of silos, and protective systems, overfilling of silo, likely to cause dust discharge to atmosphere is unlikely to occur. In addition hoses and decanting equipment on company delivery tankers are maintained in good structural integrity with low risk of failure.

As per PIRMP

action plan

When required

Mobile Plant

Incident # 6 Mobile plant, hydraulic hose or fuel tank failure

1 2 L2 N Consequence: (minor): Failure from fuel tank or hydraulic hoses would be maintain to a small localised area on site. Likelihood :( unlikely): Hose or fuel tank failure from mobile plant would be minimal as prestart and regular maintenance programs are in place

As per PIRMP

action plan

When required

to capture and prevent such occurrences. Spills kits also maintain and available in various areas.

Water discharge - waste pits / yard runoff

Incident # 7 Excessive water runoff from yard, accidental water discharge from waste pits

1 2 L2 N Consequence: (minor): Run off water enters on site sediment settling pits and then flows to Boral Quarry site retention dam where it is pumped to the quarry crushing plant for use in dust suppression / road base manufacture Likelihood :( likely): no water discharged from Boral site

N/A When required

Mobile plant/ Contractor,

Visitor

Incident # 8 Mobile plant, hydraulic hose or fuel tank failure

1 2 L2 N Consequence: (minor): Failure from fuel tank or hydraulic hoses would be maintain to a small localised area on site. Likelihood :( unlikely): Hose or fuel tank failure from mobile plant would be minimal as prestart and regular maintenance programs are in place to capture and prevent such occurrences. Spills kits also maintain and available in various areas. Inductions for all contractors demonstrating their accountabilities and responsibilities for reporting environmental incidents.

As per PIRMP

action plan

When required

Car Park Incident # 9 Ruptured fuel tank

1 2 L2 N Consequence: (minor): Failure from fuel tank or hydraulic hoses would be maintain to a small localised area on site. Likelihood :( unlikely): Hose or fuel tank failure from mobile plant would be minimal as prestart and regular maintenance programs are in place to capture and prevent such occurrences. Spills kits also maintain and available in various areas

As per PIRMP

action plan

When required

PIRMP RESPONSE ACTIONS

Incident No 1

Incident No 1

Spill of oils / lubricants

Actions Required:

• Contact all relevant people/department (refer to Immediate Reporting Contact Sheet)

• Ensure bunds are capturing full volume of product

• Ensure bund integrity is sound throughout the entire period of incident (i.e. periodic inspections)

• Contact service provider, Caltex Kurnell, (or Transpacific 02 96007185) to pump-out bund contents

• Area to be restricted to Incident Response Personnel

• Ensure spill kit available for any release from bund

• If any release from bund onto unsealed soil/surface water - Environmental Consultants to be engaged to investigate and remediate

contamination.

• Repair/replace tanks

• Refuel tanks

• Inspect bund for ongoing serviceability

Alarm raising Any personnel involved or witnessing incident to report to immediate supervisor and PIRMP actions to be implemented.

Emergency • Scott Mckay (reporting to Warwick Juno)

Controller • Call service provider (Scott Mckay)

• Spill Kit manager (Supervisor)

• Periodic inspections and update reporting of site and bund (Warwick Juno) As per Annual HSE Monitoring Plan

Scale of incident Incident would be restricted to chemical storage area with minimal external impact, however, potential for bund overflow or failure may result

in soil and surface water contamination that will require specialist investigation/remediation.

Evacuate Only if fire or explosion potential exists. Plant Manager and any advice provided by Fire Dept as part of attendance after immediate

notification.

Communications Internal:

• Plant Manager

• Ian Owen (HSE Advisor)

External mandatory:

• Immediate Reporting Contact Sheet to be used

External non-mandatory: N/A

Rescuer /

respondent +

safety checks

As per Site Emergency Plan or Fire Department as part of Immediate Reporting

Rescue + First

Aid


Clean up and

Waste disposal

Service Provider to dispose of diesel and advise on required clean-up.

Reporting and

re-preparedness

See SOPs:

• Incident Investigation GRP-HSEQ-3-02

• Emergency Planning and Response GRP-HSEQ-2-09

Incident No 2

Incident No 2

Loss of oils / gases due to filling and refueling from delivery vehicles.

Actions Required:


• Ensure bunds are capturing full volume of product

• Ensure area is well ventilated if gas is escaping cylinders


• Contact service provider (Caltex No. 1800033111 or Transpacific 02 96007185) to pump-out bund contents




contamination.


• Refuel tanks



Emergency • Scott Mckay (reporting to Warwick Juno)

Controller • Call service provider (Scott Mckay)


• Periodic inspections and update reporting of site and bund (Warwick Juno)

Scale of incident Incident would be restricted to chemical storage area with minimal external impact. However, potential for bund overflow or failure may result



notification.


• Plant Manager


External mandatory:



Rescuer /

respondent +

safety checks


Rescue + First

Aid


Clean up and

Waste disposal


Reporting and

re-preparedness

See SOPs:



Incident No 3

Incident No 3

Failure/activation of pressure release valve on bulk gas storage tank

Actions Required:


• Ensure area is isolated from FLT / Vehicles

• Contact emergency services – Fire and Rescue

• Maintain continuous waterflow to tank surface to keep tank cool until tank has vented


• Ensure spill kit available for any release of contaminated water (if requird)


contamination.


• Refuel tanks



Emergency

Controller

• Warwick Juno (reporting to Michael Morrissey)

• Scott Mckay (reporting to Warwick Juno)


Periodic inspections and update reporting of site and bund (Warwick Juno)



Evacuate Yes. Plant Manager and any advice provided by Fire Dept as part of attendance after immediate notification.


• Plant Manager


External mandatory:



Rescuer /

respondent +

safety checks


Rescue + First

Aid


Clean up and

Waste disposal


Reporting and

re-preparedness

See SOPs:



Incident No 4

Incident No 4

Loss off liquids, canola oil / liquid oxides

Actions Required:


• Ensure bunds are capturing full volume of oil/solvents


• Contact service provider (Caltex No. 1800033111or Transpacific 02 96007185) to pump-out bund contents




contamination.



Emergency

Controller


• Call service provider (Warwick Juno)


• Periodic inspections and update reporting of site and bund (Warwick Juno)




notification.


• Plant Manager


External mandatory:



Rescuer /

respondent +

safety checks


Rescue + First

Aid


Clean up and

Waste disposal


Reporting and

re-preparedness

See SOPs:



Incident No 5

Incident No 5

Cement dust release from silos due to overfill

Actions Required:

• Contact all relevant people/departments (refer to Immediate Reporting Contact Sheet)


• If necessary contact local community to advise release

• Clean up crew to be mobilized, to handle community complaints if required

• Environmental Consultants to be engaged to investigate and remediate contamination of dam, if required


Emergency

Controller


• Call Emergencies services

• Periodic inspections and update reporting of site (Warwick Juno)

Scale of incident Incident would be restricted to quarry and stockpile areas with minimal external impact. However, potential soil and surface water

contamination that will require specialist investigation/remediation.

Evacuate No


• Plant Manager


External mandatory:



Rescuer /

respondent +

safety checks


Rescue + First

Aid


Clean up and

Waste disposal


Reporting and

re-preparedness

See SOPs:



Incident No 6

Incident No 6

Mobile plant, hydraulic hose or fuel tank failure

Actions Required:



• Ensure spill kit available for any release from mobile plant & equipment

• If any release from mobile plant onto unsealed soil/surface water is investigated and remediated immediately

• Call service provider to inspect plant & equipment for serviceability


Emergency

Controller

• Scott McKay (reporting to Warwick Juno)

• Call service provider (Scott Mckay)

• Spill Kit manager (operator)

Scale of incident Incident would be localized to the area with no external impact..


notification.


• Plant Manager


External mandatory:



Rescuer /

respondent +

safety checks


Rescue + First

Aid


Clean up and

Waste disposal


Reporting and

re-preparedness

See SOPs:



Incident No 7

Incident No 7

Excessive water off from site area and concrete wash out pits

Actions Required:

• Employees, Contractor/Visitor to notify site representative of issue immediately. (induction)

• Quarry Manger to be advised


• Monitor discharge and advise when completed


Emergency

Controller

• Scott Mckay (reporting to Warwick Juno)

• Site operations manager to instruct site personnel (Scott Mckay)

Scale of incident Incident would be localized to the area with no external impact.

Evacuate No.


• Plant Manager (Warwick Juno)

External mandatory:

• Immediate Reporting Contact Sheet to be used if required


Rescuer /

respondent +

safety checks


Rescue + First

Aid


Clean up and

Waste disposal

N/A

Reporting and

re-preparedness

See SOPs:



Incident No 8

Incident No 8

Mobile plant, hydraulic hose or fuel tank failure from contractors / visitors

Actions Required:

• Contractor/Visitor to notify site representative of issue immediately. (induction)



• Ensure spill kit available for any release from mobile plant & equipment


• Call service provider to inspect plant & equipment for serviceability


Emergency • Warwick Juno (reporting to Michael Morrissey)

Controller • Call service provider (Warwick Juno)

• Spill Kit manager (operator, contractor)

Scale of incident Incident would be localized to the area with no external impact..


notification.


• Plant Manager


External mandatory:



Rescuer /

respondent +

safety checks


Rescue + First

Aid


Clean up and

Waste disposal

Service Provider to dispose of contaminates.

Reporting and

re-preparedness

See SOPs:



Incident No 9

Incident No 9

Car Park/ fuel tank failure

Actions Required:

• Contractor/Visitor to notify site representative of issue immediately. (induction)


• Ensure spill kit available for any release from mobile plant


• Call service provider to inspect plant & equipment


Emergency

Controller


• Spill Kit manager (site personnel)

Scale of incident Incident would be localized to the area with no external impact.


notification.


• Plant Manager


External mandatory:



Rescuer /

respondent +

safety checks


Rescue + First

Aid


Clean up and

Waste disposal

Service Provider to dispose of contaminate

Reporting and

re-preparedness

See SOPs:



Prepared 06.05.2016 – Warwick Juno

Documents

Boral Building Products - NSW Pollution Incident Response ... · Pollution Incident Response Management Plan (PIRMP) ... LPG Gas Tank Ref # 14 Cement Silos . ... • SWMS / SOP