PLANT RISK ASSESSMENT

TEMPLATE

All OHS, Environmental and Quality risks associated with plant operating on LORAC projects and workplaces must be assessed and have controls allocated in accordance with the Hierarchy of Control in this Plant Risk Assessment. This document contains a list of prompt points to assist in
identifying hazards of this item of plant. Additional points may be identified in the plant specific OEM manual. Prompt points 1-28 shall be assessed against different lifecycle phases of the plant, including delivery, loading, unloading, assembly, disassembly, operation, maintenance, service and
inspections.
Project: Controls and responsibility for applying the management method shall be recorded. This document is to be reviewed by the
Plant project leader or the site/plant manager, and direct supervisor of the plant item. The
Type: scoring system provides a tool to measure the perceived level of risk. Any
Manufacturer:
activity with a residual risk rating “13 and Over = Unacceptable” must be abandoned and safer alternative solution found and re-assessed.
Plant
Model: Serial number:
Location:
Plant Tasks on this project:
Assessment Undertaken by Position Title Company Date
Assessment Undertaken by Position Title Company Date
Assessment Undertaken by Position Title Company Date
Assessment Undertaken by Project Leader Company Date
Assessment Undertaken by Site/Plant Manger Company Date
Assessment Undertaken by Supervisor Company Date
Assessment Undertaken by Operator Company Date
Assessment Undertaken by Operator Company Date
Hierarchy of Control: Controls must be selected according to the Hierarchy of Control to be As Low as Reasonably Practicable (ALARP), and must comply with or exceed requirements of legislation, codes and standards

Elimination > Substitution > Isolation > Engineering > Administration > PPE
Highest Level of Control>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>Lowest Level of Control

NOTE: The above ‘Hierarchy of Controls’ must be considered and applied as part of the risk assessment process. Where ELIMINATION cannot be reasonably applied then, SUBSTITUTION, ISOLATION, ENGINEERING, ADMINISTRATION &
PPE can be considered as preferred controls in descending order

Application Probability Consequence

OHS 5 = Almost Certain 4 = Probable 3 = Moderate 2 = Unlikely 1 = Rare 5 = Multiple/Singular Fatality 4 = Nonfatal but permanent injury 3 = Injured no return to work (LTI)
2 = Injured return to work restricted duties(MTI) 1 = Injured immediate return to work (FAI)
Environement 5 = Almost Certain 4 = Probable 3 = Moderate 2 = Unlikely 1 = Rare 5 = Reputation 4 = Future work 3 = Wide Spread 2 = Local 1= Insignificant
Quality 5 = Almost Certain 4 = Probable 3 = Moderate 2 = Unlikely 1 = Rare 5 = Failure 4 = Long Term defect 3 = Major cost 2 = Minor 1 = Acceptable
1- 6 Acceptable 7-12 Acceptable with strict Control Measures or Short Duration 13 and Over = UNACCEPTABLE

PROCESS POTENTIAL SAFETY, Initial Risk Initial Risk

n

ENVIRONMENTAL and QUALITY Rating Rating

io

No. PROCESS Control Measures

at

HAZARDS
lic
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(what can go wrong) PX C= T PX C= T

A

1 OHS Delivery, loading, unloading, assembly, Human hazards through posture, repetitive 0 0
disassembly, operation, maintenance, movements, strained movements or awkward
service & inspection position

2 OHS Delivery, loading, unloading, assembly, Operating control hazards for the plant (e.g. 0 0
disassembly, operation, maintenance, control function not identified, shape or colour
ENV service & inspection inappropriate, difficult to understand)

3 OHS Delivery, loading, unloading, assembly, Person slip while ascending or descending the 0 0
disassembly, operation, maintenance, plant
service & inspection

4 OHS Delivery, loading, unloading, assembly, Person fall from the plant 0 0
disassembly, operation, maintenance,
service & inspection

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Application Probability Consequence
OHS 5 = Almost Certain 4 = Probable 3 = Moderate 2 = Unlikely 1 = Rare 5 = Multiple/Singular Fatality 4 = Nonfatal but permanent injury 3 = Injured no return to work (LTI)
2 = Injured return to work restricted duties(MTI) 1 = Injured immediate return to work (FAI)
Environement 5 = Almost Certain 4 = Probable 3 = Moderate 2 = Unlikely 1 = Rare 5 = Reputation 4 = Future work 3 = Wide Spread 2 = Local 1= Insignificant
Quality 5 = Almost Certain 4 = Probable 3 = Moderate 2 = Unlikely 1 = Rare 5 = Failure 4 = Long Term defect 3 = Major cost 2 = Minor 1 = Acceptable
1- 6 Acceptable 7-12 Acceptable with strict Control Measures or Short Duration 13 and Over = UNACCEPTABLE

PROCESS POTENTIAL SAFETY, Initial Risk Initial Risk

n
ENVIRONMENTAL and QUALITY Rating Rating
io
No. at PROCESS Control Measures
HAZARDS
lic
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(what can go wrong) PX C= T PX C= T

A

5 OHS Delivery, loading, unloading, assembly, Person struck by a load falling or by uncontrolled 0 0
disassembly, operation, maintenance, lowering or movement
service & inspection

6 OHS Delivery, loading, unloading, assembly, Person struck by an object or material falling 0 F.O.P.S. certified compliant with AS2294 for all earthmoving 0
disassembly, operation, maintenance, equipment – Certificate No.:
service & inspection

7 OHS Delivery, loading, unloading, assembly, Plant collision with people, other plant or fixed 0 0
disassembly, operation, maintenance, objects
service & inspection

8 OHS Delivery, loading, unloading, assembly, Plant rollover or become unstable 0 R.O.P.S. certified compliant with AS2294 for all earthmoving 0
disassembly, operation, maintenance, equipment – Certificate No.:
service & inspection

9 OHS Delivery, loading, unloading, assembly, Person struck or impaired by objects or fragments 0 0
disassembly, operation, maintenance, ejected from the plant
service & inspection

10 OHS Delivery, loading, unloading, assembly, Person harmed by fluid under pressure (e.g. 0 0
disassembly, operation, maintenance, hydraulic fluid, compressed air, high pressure
service & inspection water)

11 OHS Delivery, loading, unloading, assembly, Attachments not compatible with the plant (e.g. 0 0
disassembly, operation, maintenance, quick hitches, lifting points, lifting devices)
ENV service & inspection

12 OHS Delivery, loading, unloading, assembly, Contact with moving parts 0 0

disassembly, operation, maintenance,
service & inspection

13 OHS Delivery, loading, unloading, assembly, Shearing between moving parts 0 0

disassembly, operation, maintenance,
service & inspection

14 OHS Delivery, loading, unloading, assembly, Vibration cause harm, through indirect contact or 0 0
disassembly, operation, maintenance, plant becoming unstable
service & inspection

15 OHS Delivery, loading, unloading, assembly, Friction that will harm any person 0 0
disassembly, operation, maintenance,
service & inspection

16 OHS Delivery, loading, unloading, assembly, Contact with overhead powerlines 0 0

disassembly, operation, maintenance,
service & inspection

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Application Probability Consequence
OHS 5 = Almost Certain 4 = Probable 3 = Moderate 2 = Unlikely 1 = Rare 5 = Multiple/Singular Fatality 4 = Nonfatal but permanent injury 3 = Injured no return to work (LTI)
2 = Injured return to work restricted duties(MTI) 1 = Injured immediate return to work (FAI)
Environement 5 = Almost Certain 4 = Probable 3 = Moderate 2 = Unlikely 1 = Rare 5 = Reputation 4 = Future work 3 = Wide Spread 2 = Local 1= Insignificant
Quality 5 = Almost Certain 4 = Probable 3 = Moderate 2 = Unlikely 1 = Rare 5 = Failure 4 = Long Term defect 3 = Major cost 2 = Minor 1 = Acceptable
1- 6 Acceptable 7-12 Acceptable with strict Control Measures or Short Duration 13 and Over = UNACCEPTABLE

PROCESS POTENTIAL SAFETY, Initial Risk Initial Risk

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ENVIRONMENTAL and QUALITY Rating Rating
io
No. at PROCESS Control Measures
HAZARDS
lic
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(what can go wrong) PX C= T PX C= T

A

17 OHS Delivery, loading, unloading, assembly, Contact with underground services (e.g. electrical, 0 0
disassembly, operation, maintenance, gas, telecomm, water)
service & inspection

18 OHS Delivery, loading, unloading, assembly, Electrical hazard (e.g. poor insulation, poor 0 0
disassembly, operation, maintenance, earthing, contact with electrical contractors)
service & inspection

19 OHS Can any person come into contact or be Person come into contact or be harmed by 0 0
harmed by extremes of temperature? (e.g. extremes of temperature (e.g. flame, heat or cold)
flame, heat or cold)

20 OHS Delivery, loading, unloading, assembly, Expose a person to weather extremes (e.g. heat, 0 0
disassembly, operation, maintenance, cold, humidity, wet)
service & inspection

21 OHS Delivery, loading, unloading, assembly, Fumes, vapours or exhaust affect the operator or 0 0
disassembly, operation, maintenance, persons nearby (e.g. in basements and poorly
ENV service & inspection ventilated areas)

22 OHS Delivery, loading, unloading, assembly, Chemical hazards (e.g. leaks splashes from the 0 0
disassembly, operation, maintenance, plant item or the workplace)
ENV service & inspection

23 OHS Delivery, loading, unloading, assembly, Plant emits radiation (e.g. welding, 0 0
disassembly, operation, maintenance, electromagnetic rays, x-rays, microwaves, ultra
service & inspection violet, infrared, lasers)

24 OHS Delivery, loading, unloading, assembly, Noise from the plant injure the operator or those 0 0
disassembly, operation, maintenance, nearby (noise levels of the plant must be known)
ENV service & inspection

25 OHS Delivery, loading, unloading, assembly, Dust that causes breathing hazards or decreased 0 0
disassembly, operation, maintenance, visibility
ENV service & inspection

26 OHS Delivery, loading, unloading, assembly, Explosion or fire occur (e.g. from vapour, gas, 0 0
disassembly, operation, maintenance, emissions, dust, fuel)
ENV service & inspection

27 OHS Delivery, loading, unloading, assembly, Local site hazards 0 0

disassembly, operation, maintenance,
ENV service & inspection

28 OHS Delivery, loading, unloading, assembly, Plant used for purposes (eg lifting) that require 0 0
disassembly, operation, maintenance, additional controls such as anti burst valves,
service & inspection weight gauges to be fitted

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Application Probability Consequence
OHS 5 = Almost Certain 4 = Probable 3 = Moderate 2 = Unlikely 1 = Rare 5 = Multiple/Singular Fatality 4 = Nonfatal but permanent injury 3 = Injured no return to work (LTI)
2 = Injured return to work restricted duties(MTI) 1 = Injured immediate return to work (FAI)
Environement 5 = Almost Certain 4 = Probable 3 = Moderate 2 = Unlikely 1 = Rare 5 = Reputation 4 = Future work 3 = Wide Spread 2 = Local 1= Insignificant
Quality 5 = Almost Certain 4 = Probable 3 = Moderate 2 = Unlikely 1 = Rare 5 = Failure 4 = Long Term defect 3 = Major cost 2 = Minor 1 = Acceptable
1- 6 Acceptable 7-12 Acceptable with strict Control Measures or Short Duration 13 and Over = UNACCEPTABLE

PROCESS POTENTIAL SAFETY, Initial Risk Initial Risk

n
ENVIRONMENTAL and QUALITY Rating Rating
io
No. at PROCESS Control Measures
HAZARDS
lic
pp

(what can go wrong) PX C= T PX C= T

A

29 OHS Delivery Unplanned movement of plant 0 * Ensure delivery is planned and coordinated with LOR staff 0
Personal injury during unloading * Spring loaded chain binders are not to be used to secure plant
Fall from height *Avoid standing on unprotected areas at height, unload from
ground or from secure platforms

30 OHS Pre-Start check Unplanned movement 0 *ensure the equipment is fundamentally stable i.e. chalk if 0
Exposure to hazardous substances necessary
*insert extra items if needed *ensure you have read & understood the control measures and
emergency procedures on the MSDS for all oils and lubricants
associated with the equipment.
* carry out a 360 degree check around the equipment using the
plant specific pre-start check sheet
*ensure all guards are fitted and serviceable
*ensure pressure is released from all systems prior to checking
the levels

31 OHS Start / Operate Unplanned movement 0 *never operate machinery unless you are trained and 0
Entanglement competent to do so
Component failure *prior to starting any machine you must have first received
CO2 emissions familiarisation training
Slipping *prior to starting you must have read and understood the
Shearing operators manual
Falls from height *ensure all controls and levers are in neutral prior to starting
Falling objects from height *ensure the correct PPE is worn as stated in the operators
Rollover handbook and LOR requirements
*ensure equipment is started in a well ventilated area
*ensure exhaust fumes are downwind of any bystanders
*Operators to ensure all access points are free from grease or
any other contaminants.
*Never position yourself between moving objects
*Ensure any tools / materials are secured to the plant

32 OHS Inspection Unplanned movement 0 *ensure all pre start checks are carried out 0
Exposure to hazardous substances *ensure all levers are in neutral and pressure released
*ensure equipment is either blocked pinned or braced as per
manufacturer’s instructions
*ensure you have read & understood the control measures and
emergency procedures on the MSDS for all oils and lubricants
associated with the equipment.

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Application Probability Consequence
OHS 5 = Almost Certain 4 = Probable 3 = Moderate 2 = Unlikely 1 = Rare 5 = Multiple/Singular Fatality 4 = Nonfatal but permanent injury 3 = Injured no return to work (LTI)
2 = Injured return to work restricted duties(MTI) 1 = Injured immediate return to work (FAI)
Environement 5 = Almost Certain 4 = Probable 3 = Moderate 2 = Unlikely 1 = Rare 5 = Reputation 4 = Future work 3 = Wide Spread 2 = Local 1= Insignificant
Quality 5 = Almost Certain 4 = Probable 3 = Moderate 2 = Unlikely 1 = Rare 5 = Failure 4 = Long Term defect 3 = Major cost 2 = Minor 1 = Acceptable
1- 6 Acceptable 7-12 Acceptable with strict Control Measures or Short Duration 13 and Over = UNACCEPTABLE

PROCESS POTENTIAL SAFETY, Initial Risk Initial Risk

n
ENVIRONMENTAL and QUALITY Rating Rating
io
No. at PROCESS Control Measures
HAZARDS
lic
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(what can go wrong) PX C= T PX C= T

A

33 OHS Maintenacne Unplanned movement 0 *ensure all pre start checks are carried out 0
Exposure to hazardous substances *ensure all levers are in neutral and pressure released
Environmental *ensure equipment is isolated and either blocked, pinned or
Dermatological braced as per manufacturer’s instructions & guidelines
*ensure you have read & understood the control measures and
emergency procedures on the MSDS for all oils and lubricants
associated with the equipment.
*use drip trays
*report and clean up spills immediately
*use jugs and funnels to prevent spillages
*use gloves and/or barrier creams
*wash hands before hand to mouth contact i.e. eating drinking
or smoking
*change work clothing if contacted with oils and Lubricants

34 OHS Re-fuelling Fire & explosion 0 *DO NOT refuel the motor while it is in running or hot. 0
*DO NOT refuel the motor in the vicinity of sparks, a naked
flame or a person smoking.
*DO NOT refuel in confined areas without adequate
ventilation
*DO NOT refuel from any container unless it is an approved
storage container that is fitted with a pouring spout.
*Use a funnel
*Secure rammer in upright position for refuelling operation,
preferably on purpose built trolley
*DO NOT over fill the fuel tank and avoid spilling petrol when
refuelling. If spillage occurs, ensure that the area is dry before
starting the motor.
*Replace the fuel tank cap securely after refuelling.
*Allow time for vapours to clear before starting motor.
*Make sure a fire extinguisher is nearby and fully charged

35 OHS Storage Unplanned movement 0 *ensure equipment is parked/stored on firm level ground 0
Exposure to hazardous substances *ensure equipment is secured to prevent unauthorised Use
Environmental *ensure equipment is fundamentally stable to prevent any
unplanned movement i.e. chalk
*place drip tray under engine

36 OHS 0 0
37 OHS 0 0

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Application Probability Consequence
OHS 5 = Almost Certain 4 = Probable 3 = Moderate 2 = Unlikely 1 = Rare 5 = Multiple/Singular Fatality 4 = Nonfatal but permanent injury 3 = Injured no return to work (LTI)
2 = Injured return to work restricted duties(MTI) 1 = Injured immediate return to work (FAI)
Environement 5 = Almost Certain 4 = Probable 3 = Moderate 2 = Unlikely 1 = Rare 5 = Reputation 4 = Future work 3 = Wide Spread 2 = Local 1= Insignificant
Quality 5 = Almost Certain 4 = Probable 3 = Moderate 2 = Unlikely 1 = Rare 5 = Failure 4 = Long Term defect 3 = Major cost 2 = Minor 1 = Acceptable
1- 6 Acceptable 7-12 Acceptable with strict Control Measures or Short Duration 13 and Over = UNACCEPTABLE

PROCESS POTENTIAL SAFETY, Initial Risk Initial Risk

n
ENVIRONMENTAL and QUALITY Rating Rating
io
No. at PROCESS Control Measures
HAZARDS
lic
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(what can go wrong) PX C= T PX C= T

A

38 OHS 0 0

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nt Risk Assessment. This document contains a list of prompt points to assist in
loading, unloading, assembly, disassembly, operation, maintenance, service and
. The scoring system provides a tool to measure the perceived level of risk. Any
d.

Signature
Signature
Signature
Signature
Signature
Signature
Signature
Signature
xceed requirements of legislation, codes and standards

TITUTION, ISOLATION, ENGINEERING, ADMINISTRATION &

no return to work (LTI)

to work (FAI)

RESPONSIBLE
(to ensure management method is applied)

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no return to work (LTI)
to work (FAI)

RESPONSIBLE
(to ensure management method is applied)

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no return to work (LTI)
to work (FAI)

RESPONSIBLE
(to ensure management method is applied)

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no return to work (LTI)
to work (FAI)

RESPONSIBLE
(to ensure management method is applied)

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no return to work (LTI)
to work (FAI)

RESPONSIBLE
(to ensure management method is applied)

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no return to work (LTI)
to work (FAI)

RESPONSIBLE
(to ensure management method is applied)

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