PPE
What must be done before donning PPE?
Pre-Use Checks.
Where do you find Risk Assessments?
Job Procedure
What body part is injured most often, and what is percentage of this?
Hand injuries account for 60% of our total recordable injuries .
What are the three High Hazard Process (HHP) Areas in Kevlar®?
(i) PS-3 unloading through to 18” mixer outlet;
(ii) 50% caustic soda unloading through to the 23% caustic soda addition to neutralisation tanks, and strong caustic tanks;
(iii) polymer unloading to 6” mixer inlet.
When is it illegal to use the horn on your vehicle in a public street?
A horn should only be used when warning someone of any danger.It is illegal to use a horn on a moving vehicle on a restricted road, basically a road that has street lights and a 30 mph limit, between the times of 11:30 p.m. and 07:00 a.m
What PPE is required when working with/near PS-3?
Full acid suit (inc. rubber boots, long gloves and air-purged hood).
Why do we carry our risk assessments?
Risk assessments identify the hazards of a task, and who might be harmed and allows us to implement controls to mitigate these risks. It is also a legal requirement.
When was the last Medical Treatment Case(MTC) at Maydown? What happened? What injury was sustained and what preventative measures were implemented?
2 May 2025, Contractor cut finger on cable tray resulting in 4 stiches. We have now implemented a minimum of level 3 cut resistant gloves for all general tasks.
What is PSM?
(Process Safety Management is not the answer I need).
Application of management controls to operations involving hazardous materials in a way that process hazards are identified, understood, and controlled so that process-related injuries and incidents can be eliminated.
What is the 3 Metre rule with regard to PITs, and also, what MUST pedestrians do when approaching an area where a PIT is operating?
Pedestrians MUST stayed at least 3 metres away from a PIT that has a load.
When approaching an area where a PIT is operating, pedestrians MUST STOP, GIVE WAY TO THE PIT & MAKE EYE CONTACT with the PIT driver before continuing on their way.
What PPE is required when performing the following tasks?
Full Acid suit, Slovex jacket, slovex gloves, air purged hood, and chemical boots PLUS chain mail glove on non cutting hand
What tasks require a risk assessment?
All tasks require a risk assessment.
How may First Aid Case (FAC) injuries have there been at Maydown in the last 10 years?
23 since 2015
2025 19-Jun Contractor felt a discomfort when completing the task of Unload a PS-3 tanker
2024 20-Aug Contractor received electrical shock from light switch
2024 11-Jul ABM technician cut finger when taping up boxed product
2024 19-Jun Trainee eng tech injured his finger while moving valve onto test bench mount
2024 26-Jan Tech splashed with quench
2023 24-Jan Contractor slipped & fell at SM15 packing station and injured his back
2022 26-Apr Operator grazed shin when taking a pallet from the top of stacked
2022 25-Apr Operator spilled hot water on arm making tea
2021 31-Jan Irritation on right forearm, due to ingress through damaged glove.
2020 27-Nov Back pain experienced when pushing a Kevlar® Wet Waste Hamper
2020 01-Sep Cut to finger following contact with a razor within the instructor defibrillator kit.
2020 07-Feb Splashed on face/hand with Caustic filter top hat flexible hose opened
2019 07-May Exposed to a blast of compressed air, containing process liquid (pH 6.3 when Swagelok joint broke apart when operated.
2019 30-Jan Cut to right hand when IP contacted a light switch which cracked on impact.
2018 30-Sep Contractor sustained two small chemical burns on the left foot following contact with 50% Caustic during boat unload.
2018 20-Jul Contractor was removing a Kevlar® Wet Waste Hamper from SM13 hamper enclosure when they experienced pain in the left hand.
2018 17-Jul On attempting to retract SM17 breathing air line, it failed to lock when it reached the end of the line. Technician looked up and felt something hit their eye (behind their Safety Glasses). Eye was flushed on-site and at the local hospital.
2018 15-May Employee cut forehead on SM12 cabinet door as they turned quickly when the Air String-Up Gun trigger assembly separated from the gun.
2017 09-Jun Employee sparked in the eye with Quench while standing outside SM14 wet-end exclusion zone.
2017 11-Jan Employee received static shock while switching power on to a socket into which a heater was plugged.
2016 05-Sep Contractor fractured two ribs following collision with a finished product buggy at the Spinning Floor bathroom exit.
2016 04-Jan Employee sustained a chemical burn on the right middle finger following contact with 8% Sulphuric Acid due to ingress through splits in glove fingertips.
2015 20-Aug Spin Common Area Contractor raised the dry waste hamper door to remove waste yarn. As the Technician reached beneath the door to remove the yarn, one of two cables supporting the door came away from its counterbalance and the door dropped vertically. The bottom of the door struck the Technician on the left forearm and momentarily trapped the arm between the door and the grey waste hamper
What does RAGAGEP mean?
Recognised and Generally Accepted Good Engineering Practice.
What's the minimum tread depth for your car tyres?
The legal minimum tread depth for cars is 1.6 millimeters. This 1.6 mm should be in a continuous band throughout the central three-quarters of the tread width, throughout the whole of the circumference.
What PPE is required when performing the following tasks?
Full Acid suit, Slovex jacket, slovex gloves, air purged hood, and chemical boots
What is the difference between "HAZARD" and "RISK" when referring to Risk Assessment. Give an example.
Hazard is something that can cause injury or an incident e.g. Working at height
Risk is the likelihood that an injury or incident will occur e.g. Falling from height
What control did we introduce at Maydown for hand safety, in August 2021 and why did we introduce it?
4 second delay (Engineered control) on winders introduced to ensure that winders will not keep running if it does not have yarn on the dancer arm
What makes something PSM critical?
Components, equipment, or systems meeting one or more of the following criteria:
Failure may result in death or major irreversible health effects, or severe environmental impact.
The loss of primary containment of a hazardous substance.
The release of chemical energy generated within the process (e.g., deflagration, detonation, and uncontrolled reaction).
Prevent or mitigate the consequences of hazardous events that could result in death or major irreversible health effects, or severe environmental impact.
When can you wait on the yellow crisscross lines at a box junction?
You can wait in a yellow box junction if you want to turn right and are stopped from doing so by oncoming traffic, or by other vehicles waiting to turn right.
What PPE is required when performing the following tasks?
Solvex jacket, slovex gloves, Wet end visor
What is the hierarchy of control?
Elimination
Substitution
Engineering Controls
Administrative Controls
Personal Protective Equipment
How may recordable injury incident (MTC/ DAWC/ LTI) have there been at Maydown in the last 27 years?
Eleven since 1998
2 May 25 - Cut injury on cable tray (MTC)
28 Aug 21- Cut injury on hand -HK SM13 (MTC)
17 Feb19- Injured back - slip on clysar (DAWC)
8 May 18- Injured back - removing bobbin from winder (DAWC)
5 Sep 16- Twisted kneed on stairwell (DAWC)
12 Jun 16- Wrist & tendon damage requiring surgery when restringing SM12
14 Jan 12- Injured left shoulder after misjudging stair (RWC)
23 Nov 08- Twisted knee after rising up from crouched position (RWC)
15 Jun 07- Sustained fractures in right arm when coning into contact with rotating roll (DAWC)
28 Aug 98- Cut leg when placing cutting tool into pouch - MTC
24 Apr 98- Spray of casutic on face, neck & upper arm x 2 technicians (MTC)
Where would you find the Chemical Interaction Matrix?
OP103 (PSM related hazards of the process including hazardous chemicals and protective equipment).
What is the speed limit on plant approach roads (external to site boundary) and what must you never do on plant approach roads