Ravensdown Health and Safety Induction

This induction is not intended for truck driver's visiting Ravensdown sites. 

TRUCK DRIVERS

If you are a truck driver, ring the site office you're visiting for instructions. This induction is not for you.

Purpose of the induction

The purpose of this induction is to familiarize you with all the key information required for you to safely work at or visit any Ravensdown site including:​

• Our policy and commitment to health and safety​.
• Responsibilities under the Health and Safety At Work Act​.
• Sign in and access requirements​.
• PPE requirements​.
• Personal fit for duty and competency requirements​.
• Critical Risks on our site.
• Hazard, incident reporting and management requirements​.
• How incidents and emergencies are managed.
• Environmental considerations​.

Take your time, at the end of each section there is a quiz to test your understanding.

 

This form has five parts:

• Collection of information about you.
• Information about risks that exist at all Ravensdown sites.
• Information about risks that exist at the type of site you'll be at e.g. Works sites
• Site specific information that only applies to the site you'll be visiting.
• Quiz questions at each step testing your understanding.

Ravensdown's Privacy policy.

On arrival to any Ravensdown site

You must:

• Sign in
  • make contact with the person who authorised the work you are there to complete (Ravensdown work authoriser) or the person you are visiting (Ravensdown contact)
• Carry out the required pre task risk assessment process (JSA or equivalent).
• Obtain any permits required (High risk tasks)
• Get sign off from your Ravensdown supervisor, Contact or Work authoriser to commence work.

Key site rules

Sign in and out of site using SecurePass terminals (if available) Correct PPE must be worn at all times whilst on site Smoking & Vaping in signed designated areas only All accidents, incidents or hazards must be reported immediately A JSA or equivalent and/or permits must be obtained before starting any work A personal lock must be put on any plant item before starting work, when isolation is required.

Our Policy and commitment to Health and Safety

Our safety and wellbeing policy demonstrates our commitment to ensuring our people get home safe and well to their families and loved ones. This includes our team, customers, contractors and others who may be required to visit or work on our sites. 

• The key commitment we expect from anyone working at a Ravensdown site is you will do everything you can to keep yourself and anyone else on site safe. We will back you to do this.
  
  
• This means you don't start work if it's not safe to do so.
  
  
• That you STOP work and reassess if things change or become unsafe.
  
  
• We encourage you to speak up if others are not working safely.
  
  
• And if you're not comfortable talking to someone yourself about unsafe behaviour, find a supervisor or Manager who can support you.

Safety and Wellbeing Responsibilities

Workers

Under the Health & Safety at Work Act (HSWA) workers have a duty to:​

• Take reasonable care of their own health and safety
  
  
• Take reasonable care that what they do or don’t do doesn’t adversely affect the health and safety of others
  
  
• Be trained and competent for any task they are undertaking
  
  
• Cooperate with any reasonable policies or procedures Ravensdown has in place on how to work in a safe and healthy way
  
  
• Follow any reasonable instruction given by Ravensdown so that we can comply with HSWA and the regulations.
  
  
• To not participate in, aid, abet or instruct any unsafe acts.
  
  

Employers

Under the Health & Safety at Work Act (HSWA) Ravensdown must ensure it is:​

• Providing and maintaining a work environment that is without risks to health and safety
  
  
• Providing and maintaining safe plant and structures
  
  
• Providing and maintaining safe systems of work
  
  
• Ensuring the safe use, handling and storage of plant, structures and substances
  
  
• Providing adequate facilities for the welfare at work of workers in carrying out work for the business or undertaking, including ensuring access to those facilities
  
  
• Providing any information, training, instruction, or supervision that is necessary to protect all persons from risks to their health and safety arising from work carried out as part of the conduct of the business or undertaking
  
  
• Monitoring the health of workers and the conditions at the workplace for the purpose of preventing injury or illness of workers arising from the conduct of the business or undertaking.

 

Traffic Management

A Traffic Management Plan is in place for all Ravensdown sites.

All mobile plant brought to site must be regularly serviced and have installed the minimum safety requirements. 

All contractor vehicles must have a current WOF and Registration. 

Things you need to know:

• Any site one-way traffic direction must be followed by all vehicle operators. Mobile Plant are able to travel against the traffic flow where areas are provided to do so safely.
  
  
• Seatbelts must be worn when operating all heavy and light vehicles including mobile plant.
  
  
• Exclusion zones are in place around mobile plant operating areas. Permission is required to enter exclusion zones using positive communication protocol.
  
  
• Where heavy plant is operating (including road trucks) outside of a designated exclusion zone, no pedestrian or light vehicle/plant can enter within that vehicle's exclusion zone of 20 metres without positive communication being received from the operator.
  
  
• No pedestrian or light vehicle/plant can enter within 5m of that vehicle without the vehicle being fully stopped and any tool/implement (i.e. loader bucket) being on the ground.
  
  
• Vehicle and mobile plant must adhere to the site speed limits and site traffic control signs.
  
  
• Vehicles (including light vehicles, forklifts etc.) must have a flashing light (on cab) or hazard lights when entering operational areas.
  
  
• All Site personnel and contractors must be contactable using a Ravensdown RT (two way radio) when in operational areas and use them in accordance with the Positive 2 Way Radio Communication Protocol.
  
  
• Pedestrians must use designated walkways and crossing points when they are in place. When they are not you must apply "positive communication" rules with any vehicles in the area.
  
  
• Vehicles have right of way over pedestrians at all times.
  
  
• Use of mobile phones is prohibited whilst operating mobile plant or vehicles on site.
  
  
• No overtaking unless the vehicle being overtaken is stationary and the way forward is clear.
  
  
• First movement after parking or unloading should be forward. All designating parking areas are reverse parking.

 

Product Despatching Areas

Ravensdown stores and works sites all have dispatch areas where trucks are loaded.

Hazards of this area may include:

• Mobile Plant
  
  
• Dust
  
  
• Ammonia fumes
  
  
• Liquid additives
  
  
• Engulfment
  
  
• Bulk bag and pallet stacks
  
  
• Moving plant and machinery
  
  
• Noise
  
  
• Slippery floors
  
  
• Walkways and platforms

Traffic Management Rules must be adhered to when working in or around product despatching areas.

Product Storage Areas

Raw Rock, Superphosphate, SS30 and other product such as Urea, Diammonium Phosphate, Potash and Granulated Ammonium Sulphate are stored in Stores and Works sites. Often they also have overhead conveyor systems. 

Hazards of this area may include:

• Traffic Movement: loader and forklift operations, truck movements  
  
  
• Dust
  
  
• Engulfment
  
  
• Moving plant and machinery 
  
  
• Fluoride Gas
  
  
• Ammonia Gas 
  
  
• Noise
  
  
• Slippery surfaces 

Hazardous Stored Energy Areas

Ravensdown Stores, Works and Lime sites contain Hazardous Stored Energy areas.

Including: (But not limited to):

• Motor Control Centre Rooms (Electricity)
• Boiler rooms (High pressure steam)
• High pressure vessels (Compressed Air)
• Bulk Fuel Storage
• Transformers

Any work within Hazardous Stored Energy areas needs to be authorised as it may require Energy Isolations, Specialist PPE, specific training/competencies and entry requirements.

 

  

Sulphur

Elemental Sulphur and Sulphur 90 are flammable, Sulphur fires produce a toxic Sulphur dioxide gas.

Elemental Sulphur and Sulphur 90 (not burning) can produce Hydrogen Sulphide (H₂S)​ which is toxic and flammable.

Consider the presence of Sulphur to be throughout all works sites and many but not all Stores sites. Make sure this is considered during your risk assessment and put appropriate controls in place. 

If Sulphur dust enters eyes, it can sting, seek first aid immediately.

If you see a fire, move to a safe place and immediately notify a Ravensdown staff member. Do not attempt to douse the fire.

Be aware that if it is a sulphur fire, sulphur dioxide may be produced. Stay upwind of any smoke/gas emissions.

 

Safe Systems of Work

Ravensdown operates a safe system of work. The requirements are based off the risk level of the work.

You must ensure you know what level of risk assessment documentation is required for your work before commencing.

Routine work is approved work regularly conducted by Ravensdown staff or some contractors with an SOP. 

Non-routine work is work that does not have an authorised SOP.

Take 5: completed for routine work, reissuing JSAs and for approved low risk tasks (such as minor repairs in admin building). 

JSA: required for all non-routine tasks, steps out the job steps, the risks of the job and controls

All pre task risk assessments must be reviewed and approved by the Ravensdown Work Authoriser or their delgated authority.

Permits - High Risk Tasks

• Permits are required for all high-risk tasks (see 5 categories below)
• Staff and contractors require the relevant training and certificates to complete high risk work
• Permits require a Manager's or delegated authorties authorisation before starting
• Correct Competency Certificates required for Contractors are to be provided to Ravensdown

	Working at heights A rescue plan must be completed A safety watch is required All lifting equip must be certified Correct training/certificates required
	Hot Work Cold cutting to be considered first Flammable material to be removed Any remaining flammable areas to be wet down, fire blanket/shielded Fire watch must be present Firehose or extinguisher to be present Fire watch 30-120 minutes post work (depending on work area and presence of Sulphur)
	Confined space Must have a safety watch Must have a gas detector Have a confined entry certificate
	Excavation Underground service location completed Site plans consulted Breaking the ground requires a permit
	Lifting Equipment Never be underneath a suspended load Must have an exclusion zone Check weather conditions

Critical Risks

Critical Risks have been identified across the business. These are hazards which could kill or seriously injure a person if the controls are not in place.

All critical risks as with other risks must be identified assessed, and risk controls implemented to eliminate or minimize the risk of someone being harmed by them.

Ravensdown has critical risk standards that outline the minimum controls required when work includes exposure to a critical risk.

Safety Critical Risks

• Moving vehicles and equipment
  
  
• Uncontrolled hazardous energy
  
  
• Stockpile collapse
  
  
• Fall from height
  
  
• Sulphur fire
  
  
• Fire or explosion
  
  
• Dropped object(s)
  
  
• Confined space entry
  
  
• Flight failure

Fitness For Work

All individuals working at a Ravensdown site are expected to report fit for work and be able to perform assigned duties safely without any limitations due to the use or effects of:

• Fatigue.
• Drug and Alcohol.
• Prescription Medications.
• Other causes for inattention or poor decision making.

Drug and Alcohol

Ravensdown has an Alcohol and Drug Testing Policy. This is to ensure a safe and healthy workplace. It aims to eliminate unacceptable risks that alcohol and drug use brings to the workplace. 

Prescription Medicines​

If you are on prescription medicines that may impair your ability to work safely – you must raise this with your supervisor prior to commencing work to ensure steps are in place to manage this. 

Testing​

Anyone working on a Ravensdown site is subject to random drug and alcohol testing at any time. Anyone who refuses testing can and will be removed from site.

Hazard, Close Call and Incident Reporting

All incidents, close calls and new hazards that occur during work at Ravensdown must be reported immediately. 

Ensure that sufficient information about any incident is disclosed to enable Ravensdown to investigate and identify corrective actions.   

You may be required to implement corrective actions identified through the investigation process. 

 

Photo

Please take a photo of face (head and shoulders) for security purposes.

Quiz

Information common to all sites

Quiz questions for all sites

You made a mistake - the correct answers are:

Q1 - All of the above

Q2 - No, A manager or delegated athority must authorise high risk task permits.

Q3 - All Site personnel and contractors must be contactable via a Ravensdown RT when in operational areas and use them in accordance with the Positive 2 Way Radio Communication Protocol.

Q4 - Ravensdown Work Authoriser, Site Manager, or applicable business partner.

Please use the "Back" button to go and correct your answers.

Nice work you got all the questions right!

✔️😊

Works Personal Protective Equipment

Minimum PPE to be worn on
site includes:

• Hard Hat.
• Safety Footwear.
• Hi-vis.
• Safety Glasses.

Additional PPE may be required as part of a task or working in a specific area. This will be determined by carrying out a pre task risk assessment prior to work commencing.

Site specific information

Christchurch Works specific induction information

Christchurch Works Signing in and out

All people must sign in and out when entering and exiting the site. The red boxes below show the location of the sign in terminals for contractors and visitors. Staff must use their security fobs.

You can sign in and out at the admin building or maintenance, or where there are QR codes using your smart phone.  

All contractors and temp staff must be escorted by a Ravensdown Worker to their workplace on their first visit. All visitors must be escorted by a Ravensdown staff member at all times, during all visits.

If you are working onsite outside normal operating hours, you need to organise this with Christchurch Works Management.

Christchurch Works high risk areas

Christchurch works - Acid plant and Sulphur melter

Hazards of this area include:

• Sulphur (solid, dust, & molten) - Fire Risk
• Sulphuric Acid- Burn Risk
• Hydrogen Sulphide Gas- Gas Inhalation Risk
• Sulphur Dioxide and Trioxide- Gas Inhalation Risk
• High Pressure Steam- Burn Risk
• Boiler
• Noise
• Heat

Note: Treat any liquid in this area as acidic.

All work in this area must be authorised by Ravensdown Acid Plant Engineer. If you are working in this area, you must notify the control room in advance to gain access.

Christchurch works - Manufacture

Hazards of this area include:

• Fluoride Gas- Gas Inhalation Risk
• Dust- Eye Irritation- Inhalation Risk 
• Sulphuric Acid and Caustic Soda- Burn Risk
• Moving plant and machinery
• Steam
• Noise
• Walkways and platforms

Note: Treat any liquid in this area as acidic
Note: This is an earthquake prone building, there are earthquake safety pods on the ground floor. 

All work in this area must be authorised by a Ravensdown Manufacturing Operator. Only authorised persons can enter this area.

Christchurch works - Scrubber

Hazards of this area include:

• Fluoride Gas- Gas Inhalation Risk
• Flurosilicic Acid- Burn Risk
• Caustic Soda- Burn Risk
• Ozone- Gas Inhalation Risk
• Moving plant and machinery 
• Steam
• Noise
• Walkways and platforms

Note: Treat any liquid in this area as acidic

All work in this area must be authorised by a Ravensdown Manufacturing Operator. 
If you are working in this area, you must report to the manufacture control room.

Christchurch works - Maintenance

The Maintenance Workshop is located at the eastern end of the site. The workshop contains a machine shop, a hot work bay, offices and parts store.

Hazards of this area include:

• Machining and maintenance equipment
• Hot work, e.g. welding
• Gas store
• Lifting equipment
• Forklift operations
• Light vehicles
• Noise
• Welding and grinding fumes

All work in this area must be authorised by the Maintenance Manager, you must gain permission prior to using any equipment.

The hot work bay is not to be treated as a thoroughfare, entry to the workshop is via the kitchen area or southern door only.

Christchurch works - Intake

All bulk products brought into Christchurch Works are unloaded via the Intake.
This building is an enclosed shed over a hopper where trucks drop their product through a floor grate into the hopper. Product then travels along a conveyor up the incline into the stores and is transported along a series of conveyors to be poured into the storage shed.

Hazards of this area include:

• Mobile Plant and truck movement
• Dust
• Ammonia fumes
• Moving plant and machinery
• Noise
• Walkways and platforms

Traffic Management Rules must be adhered to when working in or around the Intake.

Christchurch works - Product stores

Raw Rock, Superphosphate, SS30 and other product such as Urea, Diammonium Phosphate, Potash and Granulated Ammonium Sulphate are stored in large storage sheds which are interconnected by a central alleyway and overhead conveyor systems. 

Hazards of this area include:

• Traffic Movement- Loader and forklift operations, occasionally truck movements  
• Dust
• Engulfment
• Moving plant and machinery 
• Fluoride Gas
• Ammonia Gas 
• Noise
• Slippery surfaces 

You must establish "positive communications" with mobile plant prior to entry into any operational areas.
If you do not get permission from the driver, do not proceed.

Christchurch Works - Despatch

All products despatched from Christchurch Works are loaded via 3 bulk despatch points or the bag store.

Hazards of this area may include:

• Mobile Plant
• Dust
• Ammonia fumes
• Liquid additives
• Container movements
• Engulfment
• Bulk bag and pallet stacks
• Moving plant and machinery
• Noise
• Slippery floors
• Walkways and platforms

Traffic Management Rules must be adhered to when working in or around the despatch zones.

Christchurch works - emergency response

If you hear the evacuation alarm, stop ALL work, evacuate the building immediately by the nearest exit and report to one of the three assembly areas. 

An Emergency Response Plan is in place for all reasonably foreseeable events for Christchurch Works. The emergency response procedures are available throughout the site. 

• In the event of an emergency dial 111 and ask for the required service and activate the manual call points located throughout the site.
  
  
• Emergency equipment, including fire fighting equipment is located throughout the site.
  
  
• First aid kits are in control rooms and the admin/cafeteria buildings.
  
  
• Two Defibrillators are available onsite
  • One is located at the front entry of the Admin building
  • The other is outside the maintenance office.
    
    
• Additional first aid equipment such as Diphoterine spray, eye wash and safety shower stations are available at the Acid Plant and Manufacturing Plant. 

Christchurch Works - KiwiRail Lease Land

Ravensdown lease a small parcel of land from Kiwi Rail located in the far North-East corner of the site, between the bag store and B Despatch (as pictured).

Any incidents with an actual or potential severity of major or above, or an incident which impacts the land/soil i.e. a hazardous substance spill must:

• Be reported immediately to the Works Manager and/or the Health Safety and Well-being Business Partner
• The works manager and/or Health Safety and Wellbeing Business Partner must report the incident to kiwi rail’s lease point of contact.
   

Information from the investigation summary may be required by KiwiRail.

 

Christchurch works - Environment

Christchurch Works has a resource consent to discharge contaminants to air. Make sure your work adequately controls  discharges to air such as fume, dust, noise and odours that may affect the environment, our workers or neighbours.

Stormwater is collected in  three stormwater basins. Water quality is regularly monitored. Never dispose of any waste into our stormwater drains. If you have a product spill of any type/size, it must be cleaned up immediately. 

Wash bay material is managed in the ‘green ponds’. There are limitations to the types of materials that can be reused on site or sent to tradewaste, it is extremely important that only mobile plant and approved equipment are cleaned here.

General waste, recycling and untreated wood skips are across the site. Use the correct skip for the type of waste being disposed of. These skips are strictly for Ravensdown waste only. Consider additional waste management requirements for your task. 

Christchurch works - Induction quiz questions

Dunedin Works specific induction information

NOTE - Ravensdown Dunedin Works is an MPI Trasitional facility.

 

Dunedin Works: 102 Ravensbourne Road.

Enter to the site turning right off Ravensbourne Road

From the entry ramp turn right towards the admin building.

Reverse parking areas are available in front of the office block.

When exiting the site there is no right turn at the top of the exit ramp and be careful of traffic coming from your right along Ravensbourne Road.

Dunedin Works Signing in and out

All people must sign in and out when entering and exiting the site. The red squares above show the location of the sign in terminals to be used by contractors and visitors. Staff must sign in using their security fobs.

You can sign in and out at either the admin or maintenance terminals.

 

On their first visit all contractors and temp staff must be escorted by a Ravensdown worker to their workplace. All visitors must be escorted by a Ravensdown staff member at all times, during all visits.

If you wish to work onsite outside of normal operating hours, you need to organise this with Dunedin Works Management.

All contractors are required to carry a Ravensdown RT while on site. These need to be used prior to entry into any exclusion zones. If the evacuation siren is activated turn your RT to Channel 2 to hear any further instructions.

RT Channels to use:

Channel 1:      Despatch areas

Channel 2:      Manufacture

Channel 5:      Acid Plant & Melter

 

 

Dunedin works - Acid plant and Sulphur melter

Hazards of this area include:

• Sulphur (solid, dust, & molten) - Fire Risk
• Molten Sulphur – Burns Risk
• Sulphuric Acid- Burn Risk
• Hydrogen Sulphide Gas- Gas Inhalation Risk
• Sulphur Dioxide and Trioxide- Gas Inhalation Risk
• High Pressure Steam- Burn Risk
• Boiler
• Noise
• Heat

Note: Treat any liquid in this area as acidic.

All work in this area must be authorised by the Ravensdown Acid Plant Engineer. If you are working in this area, you must notify the control room in advance to gain access.

[Sulphur Melter and Storage]

[Acid Plant]

 

Dunedin works - Manufacture

Hazards of this area include:

• Fluoride Gas- Gas Inhalation Risk
• Dust- Eye Irritation- Inhalation Risk
• Sulphuric Acid and Caustic Soda- Burn Risk
• Molten Sulphur – Burns Risk
• Moving plant and machinery
• Steam
• Noise
• Walkways and platforms

Note:

1. Treat any liquid in this area as acidic.
2. When the plant is operational, hearing protection is required inside the manufacture building.

All work in this area must be authorised by the Manufacturing Leading Hand. Only authorised persons can enter this area.

 

Dunedin works - Maintenance

The Maintenance Workshop is located at the southern end of the site. The workshop contains a machine shop, a hot work bay, offices and parts store.

Hazards of this area include:

• Machining and maintenance equipment
• Hot work, e.g. welding
• Gas store
• Lifting equipment
• Forklift operations and ATV (Buggy)
• Light vehicles
• Noise
• Welding and grinding fumes

All work in this area must be authorised by the Maintenance Manager or Maintenance Coordinator and you must gain permission prior to using any equipment. The welding bay is not to be treated as a thoroughfare.

Dunedin works - Intake

Bulk products brought into Dunedin Works are either unloaded from Ships at the wharf or delivered by truck and tipped directly into storage bays.
Product is unloaded from the ships using the ship cranes and then travels along a conveyor up the incline into the main building and is transported along a series of internal conveyors to be poured into the storage shed.

Hazards of this area include:

• Mobile Plant and truck movement
• Dust
• Ammonia fumes
• Moving plant and machinery
• Noise
• Walkways and platforms

The Railway Crossing to the wharf is not controlled by lights or barriers. 

• Watch out for trains when crossing to and from the wharf.
• Be very aware of cyclists and pedestrians on the shared path.
• When crossing the train tracks with vehicles/mobile plant, a spotter MUST be used at all times.

Traffic Management Rules must be adhered to when working in or around the intake areas

Dunedin works - Product stores

Raw Rock, Superphosphate, SS30 and other product such as Urea, Di-ammonium Phosphate, Potash and Granulated Ammonium Sulphate are stored in large storage sheds which are interconnected by a central alleyway and overhead conveyor systems. 

Hazards of this area include:

• Traffic Movement - Loader, forklift and truck movements
• Dust
• Engulfment
• Moving plant and machinery
• Fluoride Gas
• Ammonia Gas
• Noise
• Slippery surfaces

You must notify loader drivers of entry and exit into Exclusion Zones and any storage area by using an RT. If you do not get permission from the driver, do not proceed. 

Dunedin Works - Despatch

All products despatched from Dunedin Works are loaded via 2 bulk despatch points (A or B) or through the bag store.

Hazards of this area may include:

• Mobile Plant and heavy road vehicles
• Dust
• Ammonia fumes
• Container movements
• Engulfment
• Bulk bag and pallet stacks
• Moving plant and machinery
• Noise
• Slippery floors
• Walkways and platforms

Traffic Management Rules must be adhered to when working in or around the despatch zones.

[A Despatch]

[B Despatch]

High risk areas

The following images identify areas of high-risk activities on our site, including the storage areas for Fuel, chemicals, Sulphur and Acid.

Dunedin works - emergency response

If you hear the evacuation alarm, stop ALL work, evacuate the building immediately by the nearest exit and report to one of the three assembly areas which are located: 

• Bottom of entry ramp
• Landside of wharf entrance
• Truck entrance to Moller park

An Emergency Response Plan is in place for all reasonably foreseeable events for Dunedin Works. The emergency response procedures are available throughout the site. 

• In the event of an emergency dial 111 and ask for the required service and activate one of the manual call points located throughout the site.
• Emergency equipment, including firefighting equipment is located throughout the site.
• First aid kits are in control rooms and the admin/cafeteria buildings.
• A Defibrillator is available at the front entry of the Admin building.
• Additional first aid equipment such as Diphoterine spray, eye wash and safety shower stations are available at the Acid Plant and Manufacturing Plant and around chemical storage areas. 

Dunedin works – Environment

Dunedin has 12 different environmental consents and approvals that are highly prized assets to the company. 

Right across the country, we have a high care factor when it comes to the environment. Each site has a dedicated environmental manager.

We have over 200 specific conditions in Dunedin alone, that we need to adhere to on a day to day, week to week basis. 

1. When completing your take 5 or JSA, consider if there are any extra environmental risks or controls required? In most cases, anything specific that we require, we will have let you know by this stage.
2. Use our recycling facilities.
3. Nothing other than water down the drain/into stormwater system or direct to the harbour – any spills must be reported to a manager.
4. Take particular care around noise, dust and gasses that may leave the site.
5. Any questions, or unsure about our expectations, please ask.

Dunedin Works - Induction quiz questions

Napier Works specific induction information

• Napier Works main carpark and office - 90 Waitangi Road - All visitors and contractors to report here on their first time to site.
• Main truck and vehicle entrance to site located at south end of Waitangi road, with site being one way exiting at the northern end.
• Acid Plant and Melter carpark located at southern point of Waitangi Road at entrance from SH51.
• Reverse parking required everywhere on site
• Speed limit on site is 15kmh

Napier Works Signing in and out

All people must sign in and out when entering and exiting the site. The red squares in the image above show the location of the sign in/out terminals to be used by contractors and visitors. Staff must sign in using their security fobs.

On their first visit, all contractors and temporary staff must be escorted by a Ravensdown worker to their workplace. All visitors must be escorted by a Ravensdown staff member at all times, during all visits.

If you wish to work onsite outside of normal operating hours, you need to organise this with Napier Works Management.

All contractors are required to carry a Ravensdown RT while on site (one RT for a work group may be allocated). These need to be used prior to entry into any exclusion zones. If the evacuation siren is activated turn your RT to Channel 4 to hear any further instructions.

RT Channels to use:

Channel 1:       Manufacturing

Channel 2:       Despatch

Channel 3:       Acid Plant & Melter

Channel 4:       In the event of emergency.

Napier Works high risk areas

Napier Works - Acid plant and Sulphur melter

Hazards of this area include:

• Sulphur (solid, dust, & molten) - Fire Risk.
• Molten Sulphur - Burns Risk.
• Sulphuric Acid - Burn Risk.
• Hydrogen Sulphide Gas - Gas Inhalation Risk.
• Sulphur Dioxide and Trioxide - Gas Inhalation Risk.
• High Pressure Steam - Burn Risk.
• Boiler.
• Noise.
• Heat.

Note: Treat any liquid in this area as acidic.

All work in this area must be authorised by the Ravensdown Acid Plant Engineer. If you are working in this area, you must notify the control room in advance to gain access.

Napier Works - Manufacture

Hazards of this area include:

• Fluoride Gas - Gas Inhalation Risk.
• Fluosilicic Acid (FSA).
• Dust- Eye Irritation - Inhalation Risk.
• Sulphuric Acid and Caustic Soda - Burn Risk.
• Molten Sulphur - Burns Risk.
• Moving plant and machinery.
• Steam.
• Noise.
• Walkways and platforms.

Note:

1. Treat any liquid in this area as acidic.
2. When operational, hearing protection is required inside the manufacture building.

All work in this area must be authorised by a Ravensdown Manufacture Operator. ​

If you are working in this area, you must report to the control room.  Follow PPE requirements for this area.

 

Napier Works - Scrubber

Hazards of this area include:

• Fluoride Gas - Gas Inhalation Risk.
• Flurosilicic Acid - Burn Risk.
• Caustic Soda - Burn Risk.
• Moving plant and machinery.
• Steam.
• Noise.
• Walkways and platforms.

Note: Treat any liquid in this area as acidic.

All work in this area must be authorised by a Ravensdown Manufacture Operator. ​
If you are working in this area, you must report to the control room.

Follow PPE requirements for this area.

Napier Works - Maintenance

The Maintenance Workshop contains a machine shop, welding bay, mobile plant service garage & offices. The parts store is located at the south end of the site adjacent to the Acid Plant

Hazards of this area include:

• Machining and maintenance equipment
• Welding equipment - hotwork
• Gas store
• Lifting equipment
• Forklift operations and ATV (Buggy)
• Light vehicles
• Noise
• Welding and grinding fumes

All work in this area must be authorised by the Maintenance Co-Ordinator, you must gain permission prior to using any equipment.

All vehicles to park in main car park.

Napier Works - Intake

This building is an enclosed shed over a hopper where trucks drop their product through a floor grate into the hopper. Product then travels along a conveyor into the storage sheds.

Hazards of this area include:

• Sulphur
• Mobile Plant and truck movement
• Dust
• Fumes
• Moving plant and machinery
• Noise
• Walkways and platforms
• Confined space areas

Traffic Management Rules must be adhered to when working in or around the intake areas.

Napier Works - Product stores

Raw Rock, Superphosphate, SS30 and other product such as Urea, Potash and Granulated Ammonium Sulphate are stored in large storage sheds which are interconnected by a central alleyway (Canopy).

Hazards of this area include:

• Traffic Movement- Loader and forklift operations, occasionally truck movements
• Dust
• Engulfment
• Moving plant and machinery
• Fluoride Gas
• Noise
• Slippery surfaces

You must notify Despatch, Manufacturing and Loader Drivers you are entering their area and exit into the central alleyway (Canopy) and any shed using the RT. DO NOT proceed until you have clear communication giving you permission to proceed. Failing to do this may result in a serious accident or worse.

Napier Works - Despatch

All trucks are loaded via two bulk despatch points or the bagging pick-up areas, shown with green arrows.

Hazards of this area may include:

• Mobile Plant
• Dust
• Fumes
• Container movements
• Engulfment
• Bulk bag and pallet stacks
• Moving plant and machinery
• Noise
• Walkways and platforms

Traffic Management Rules must be adhered to when working in or around the despatch zones.

High Risk Areas

The following images identify areas of high-risk activities on our site, including the storage areas for fuel, chemicals, sulphur and acid.

Napier Works - emergency response

If you hear the evacuation alarm, stop ALL work, evacuate the building immediately by the nearest exit and report to one of the three assembly areas. 

An Emergency Response Plan is in place for all reasonably foreseeable events for Napier Works. The emergency response procedures are available throughout the site. 

• In the event of an emergency dial 111 and ask for the required service and activate the manual call points located throughout the site.
• Emergency equipment, including firefighting equipment is located throughout the site.
• First aid kits are in control rooms and the admin/cafeteria buildings.
• A Defibrillator is available at the front entry of the Admin building.
• Additional first aid equipment such as Diphoterine spray, eye wash and safety shower stations are available at the Acid Plant and Manufacturing Plant and around chemical storage areas. 

Napier Works – Environment

Right across the country, we have a high care factor when it comes to the environment. Each site has a dedicated environmental business partner. Each sites operation relies on meeting strict consenting requirements, that are achievable by everyone onsite making an effort.

1. Nothing other than water down the drain/into stormwater system or direct to waterways – any spills must be reported to a manager.
2. Take particular care around noise, dust and gasses that may leave the site.
3. When completing your take 5 or JSA, consider if there are any extra environmental risks or controls required? In most cases, anything specific that we require, we will have let you know by this stage.
4. Use our recycling facilities.

Any questions, or unsure about our expectations, please ask.