- Control Room Shift Log8
- Permit and Isolation Register8
- Incident and Process Safety Event Register8
- Bulk Transfer and Tank Inventory Register8
Process safety first
CAQA Hydra Chemical and Refining manufactures and distributes process chemicals for the mining, water treatment and industrial markets of Western Australia.
CAQA Hydra Chemical and Refining, chemical processing and refining
CAQA Hydra Chemical and Refining manufactures and distributes process chemicals for the mining, water treatment and industrial markets of Western Australia. The Kwinana plant produces ferric sulfate and ferric chloride coagulants in batch reactors, dilutes and blends caustic soda and acid grades, and runs a solvent recovery unit that distils used industrial solvents into refined grades for resale. The Kwinana Beach terminal stores bulk caustic, acid, solvents and diesel in tank farms and loads road tankers and isotainers for customers from Perth to the Pilbara. The Karratha depot blends and distributes water treatment chemicals to mine sites and remote communities.
The business is organised into six departments. Process Operations runs the Kwinana plant continuously on a four-panel, twelve-hour shift roster with a central control room and outside operators covering the reactor building, the solvent recovery column and the utilities area. The Bulk Liquids Terminal operates on day and afternoon shifts with a night gauging round. Maintenance and Asset Integrity, Process Safety and Emergency Response, the Laboratory and Product Quality team and Technical Services and Environment work day shifts with on-call cover. The Kwinana plant is a licensed major hazard facility and operates under an accepted safety case.
Process safety first
We keep hazardous materials inside the pipes and tanks. If a control is not in place, the job does not start.
Discipline
We follow the procedure, use the permit and record what we did, every shift, because that is what keeps a major hazard facility safe.
Openness
We report every near miss and upset without blame so that we learn before something worse happens.
Reliability
Customers in remote places depend on our deliveries, so we plan, maintain and deliver on time.
Services and operations
To make and deliver the chemicals our customers rely on without harm to people, the environment or the community around our sites.
Coagulant manufacture
Batch production of ferric sulfate and ferric chloride coagulants for water and wastewater treatment plants, made to specification in the Kwinana reactor building and tested before release.
Caustic and acid supply
Dilution, blending and bulk supply of sodium hydroxide, sulfuric acid and hydrochloric acid grades to mining, alumina and industrial customers across the state.
Solvent recovery and refining
Collection and distillation of used industrial solvents into refined grades, reducing waste for customers and returning product to the market with a certificate of analysis.
Bulk liquids storage and handling
Tank storage, road tanker and isotainer loading and inventory management at the Kwinana Beach terminal for Hydra products and third party chemicals.
Regional distribution and site blending
Blending and delivery of water treatment chemicals from the Karratha depot to mine sites and remote communities, with dosing support on request.
Technical and process support
Process engineering, dosing trials, chemical compatibility advice and emergency response support for customers who use Hydra products.
Six departments, one workplace
Each department has a purpose, a lead, responsibilities, performance measures and the systems it works in. Students are placed in a department by their scenario.
Process Operations
Operates the Kwinana reactor building, solvent recovery column and utilities continuously from the central control room and the fi...
Visit departmentBulk Liquids Terminal and Logistics
Receives, stores and dispatches bulk chemicals at the Kwinana Beach terminal, manages tank inventory and gauging, loads road tanke...
Visit departmentProcess Safety and Emergency Response
Owns the safety case, the permit to work system, incident investigation, process safety performance indicators, emergency planning...
Visit departmentMaintenance and Asset Integrity
Keeps reactors, columns, exchangers, pumps, valves, instruments, tanks and pipework fit for service through inspection, planned ma...
Visit departmentLaboratory and Product Quality
Samples and tests raw materials, batches, tank contents and finished products, issues certificates of analysis, advises operators ...
Visit departmentTechnical Services and Environment
Provides process engineering, optimisation and debottlenecking, manages the management of change process, holds the environmental ...
Visit departmentWorking systems with real records
Every system is live in your browser: create, update, search, move cards on a board and export what you did. Reset returns the seed data at any time.
Control Room Shift Log
Records every operating event, batch, reading, sample result, override and handover from the control room and the field for each shift.
8 recordsPermit and Isolation Register
Tracks every permit to work, isolation certificate and blind from request to close-out and records permit audits.
8 recordsIncident and Process Safety Event Register
Logs injuries, near misses, losses of containment, safety system activations, limit excursions and environmental events with tier, investigation and actions.
8 recordsBulk Transfer and Tank Inventory Register
Records every receipt, internal transfer and dispatch of bulk product with tank, quantity, gauging and reconciliation.
8 recordsManagement of Change Register
Tracks every management of change request from submission to close-out including temporary changes, overrides and their expiry dates.
8 recordsInbox
8 work requests from managers and colleagues, each linked to a scenario or a document.
Open inboxEight workplace scenarios
Sign in as a role, read the brief, work through the tasks using the documents and systems, then print an evidence summary for your assessor.
Sample, test and adjust ferric chloride batch FC-26-0210
You are a laboratory technician in Laboratory and Product Quality working with the outside operator.
Open scenario Entry 2 to 3 hoursReceive a hydrochloric acid road tanker into T-105
You are a terminal operator at the Kwinana Beach terminal.
Open scenario Intermediate 4 to 5 hoursStart up the solvent recovery column after the pump repair
You are the panel operator for the solvent recovery unit on day shift, Panel C.
Open scenario Intermediate 4 to 5 hoursPrepare and isolate Reactor 1 for the bottom flange gasket replacement
You are an outside operator acting as isolation authority for Reactor 1.
Open scenario Intermediate 2 to 3 hoursRespond to a reactor high temperature abnormal situation
You are the panel operator for the reactor building on Panel C during a simulator exercise.
Open scenario Advanced 5 to 6 hoursInvestigate the T-105 high level alarm activation
You are a process safety engineer in Process Safety and Emergency Response.
Open scenario Advanced 5 to 6 hoursDebottleneck the solvent recovery column through management of change
You are a process engineer in Technical Services and Environment.
Open scenario Advanced 6 to 8 hoursPlan and run the October emergency exercise with emergency services
You are the emergency response coordinator in Process Safety and Emergency Response.
Open scenarioNotice board All notices
- Safety Receipts to T-105 restricted
9 September 2026 - Safety Sampling protective equipment
8 September 2026 - Compliance Safety case revision consultation
10 September 2026
Coming up Calendar
- 14/09Caustic ship receipt, Kwinana Beach terminal
6:00 am, Kwinana Beach terminal - 17/09Permit issuer and isolation authority refresher
8:00 am, Training room, Kwinana - 23/09Monthly process safety review
1:00 pm, Boardroom, Kwinana - 25/09Reactor 2 shutdown planning meeting
10:00 am, Training room, Kwinana
Mapped to the Chemical, Hydrocarbons and Refining
Every scenario lists the current units of competency and qualifications it supports, with assessor notes and a printable evidence summary. Use it with your own assessment tools or ask CAQA for a matched kit.