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Plant Maintenance

OH&S Plant Obligations make Good Business Sense!


Capability by Design Pty Ltd.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

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
Capability by Design Pty Ltd.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

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)


Capability by Design Pty Ltd.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

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
Capability by Design Pty Ltd.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

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?
Capability by Design Pty Ltd.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

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 Reqts AS/NZS 3907 Guidelines for Configuration Management
Capability by Design Pty Ltd.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

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.

Capability by Design Pty Ltd.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

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

Capability by Design Pty Ltd.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

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.

Capability by Design Pty Ltd.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

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.

Capability by Design Pty Ltd.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

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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
Capability by Design Pty Ltd.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

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List of Plant

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Plant Details

Capability by Design Pty Ltd.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

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Plant Regulation Requirements

Capability by Design Pty Ltd.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

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Designed and Actual Use

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HAZARD Analysis

Capability by Design Pty Ltd.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

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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
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Capability by Design Pty Ltd.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

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
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Capability by Design Pty Ltd.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

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
Capability by Design Pty Ltd.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

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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?
Capability by Design Pty Ltd.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

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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
Capability by Design Pty Ltd.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

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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

Capability by Design Pty Ltd.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

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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
Capability by Design Pty Ltd.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

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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.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

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Plant, Operations and Maintenance

Capability by Design Pty Ltd.. Phone: 029 681 6334 Fax: 029 681 6335 Email: kohler@tpg.com.au

Capability by Design Pty Ltd.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

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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
Capability by Design Pty Ltd.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

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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.
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Capability by Design Pty Ltd.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

How can Capability by Design help you?


Plant Analysis and OH&S software tools using Assure Plant maintenance analysis & analysis tools tailoring Strategy Based Learning for developing a learning environment in the workplace

Plant management
information systems auditing and developing Plant maintenance audits Plant Management Policy Manual development

Business Centred
Maintenance Implementation Programme(s)

Capability by Design Pty Ltd.. Phone: 02 9760 2094 Fax: 02 9760 2941 Email: Peter.Kohler@cbdesign.com.au

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