Product Overview

Summary: This Safe Operating Procedure sets out a clear, step‑by‑step method for safely synchronising emission control systems so plant and equipment operate within Australian environmental and WHS requirements. It helps organisations coordinate sensors, control units and treatment devices to minimise harmful emissions, prevent system failures and demonstrate due diligence to regulators.

Emission control systems are becoming increasingly complex, integrating sensors, programmable logic controllers (PLCs), exhaust after‑treatment units, scrubbers, filters and monitoring software. When these components are not correctly synchronised, organisations face heightened safety risks, equipment damage, non‑compliance with licence conditions and avoidable downtime. This Emission Control System Synchronisation SOP provides a structured, repeatable process for aligning control logic, calibration settings and interlocks so that emission reduction technologies work together safely and reliably.

Tailored for Australian industrial, manufacturing, mining, transport and utilities environments, the procedure guides workers through planning, lockout/tagout, system verification, staged synchronisation, functional testing and documentation. It addresses the intersection between WHS obligations and environmental performance, supporting duty holders to manage risks associated with toxic gases, diesel particulate, flammable atmospheres and confined spaces. By standardising how synchronisation is carried out and recorded, this SOP reduces reliance on informal practices, supports competency‑based training, and provides a defensible audit trail during inspections or incident investigations.

Key Benefits

• Ensure emission control systems operate within design parameters and regulatory limits through a consistent synchronisation process.
• Reduce the risk of exposure to hazardous gases, particulates and fumes arising from malfunctioning or bypassed emission controls.
• Minimise unplanned downtime and costly equipment damage caused by unsynchronised sensors, controllers and treatment devices.
• Demonstrate compliance with Australian WHS and environmental obligations through structured records and verification steps.
• Standardise training for technicians and operators, improving competence and reducing variability in system setup and adjustment.

Who is this for?

• Plant Managers
• Maintenance Supervisors
• Control Systems Engineers
• Electrical and Instrumentation Technicians
• WHS Managers
• Environmental and Sustainability Managers
• Operations Managers
• Commissioning Engineers
• Fleet Maintenance Coordinators (diesel and mobile plant)
• Compliance and Risk Managers

Hazards Addressed

• Exposure to toxic exhaust gases (e.g. carbon monoxide, nitrogen oxides, sulphur oxides).
• Inhalation of diesel particulate matter and fine airborne particulates.
• Fire and explosion risks from flammable gases or vapours in poorly ventilated or hazardous areas.
• Asphyxiation risks from oxygen displacement in confined or poorly ventilated spaces.
• Thermal burns and contact injuries from hot exhaust components and treatment units.
• Electrical shock or arc flash during work on powered control panels and instrumentation.
• Mechanical hazards from moving parts during system testing and commissioning.
• Environmental contamination and regulatory breaches due to uncontrolled emissions.

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and System Overview
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Site Requirements
• 5.0 Pre‑Synchronisation Planning and Risk Assessment
• 6.0 Isolation, Lockout/Tagout and Permit Requirements
• 7.0 Required Tools, Test Equipment and Personal Protective Equipment (PPE)
• 8.0 System Inspection, Verification and Baseline Checks
• 9.0 Sensor Calibration and Signal Validation Procedure
• 10.0 Controller, PLC and Software Configuration Alignment
• 11.0 Synchronisation of Emission Treatment Devices (filters, SCR, scrubbers, etc.)
• 12.0 Functional Testing, Interlock Verification and Alarm Set‑point Checks
• 13.0 Ventilation, Atmospheric Monitoring and Gas Testing Requirements
• 14.0 Documentation, Data Logging and Change Management
• 15.0 Non‑Conformance Management and Troubleshooting Guide
• 16.0 Emergency Procedures and System Bypass Controls
• 17.0 Training, Competency and Refresher Requirements
• 18.0 Review, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and relevant state and territory WHS Acts and Regulations
• Environment Protection and Biodiversity Conservation Act 1999 (Cth) and relevant state and territory environmental protection legislation
• Safe Work Australia – Managing Risks of Hazardous Chemicals in the Workplace Code of Practice
• Safe Work Australia – Confined Spaces Code of Practice
• AS/NZS 3000:2018 Electrical installations (Wiring Rules)
• AS/NZS 60079 series: Explosive atmospheres (for hazardous areas classification and equipment)
• AS/NZS ISO 14001:2016 Environmental management systems – Requirements with guidance for use
• AS/NZS 2290.3:2018 Electrical equipment for coal mines – Maintenance and overhaul (where applicable to underground diesel and ventilation systems)
• National Environment Protection (Ambient Air Quality) Measure (NEPM) – for air quality and emission considerations