our new approach to reporting - sec.gov | home new approach to reporting. ... , approximately 500...

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6-K1y90687.htmHEALTH SAFETY ENVIRONMENT AND COMMUNITY REPORT 2003

__________________________________________________________________________________

SECURITIES AND EXCHANGE COMMISSION

Washington, D.C. 20549

_______________

FORM 6-K

REPORT OF FOREIGN ISSUER

PURSUANT TO RULE 13a-16 OR 15d-16OF

THE SECURITIES EXCHANGE ACT OF1934

For the Date of 30September 2003

BHP Billiton Limited

ABN 49 004 028 077

Level 27, 180 Lonsdale Street

Melbourne Victoria 3000

Australia

Indicate by check mark whether the registrantfiles or will file annual reports under cover of Form 20-F or Form 40-F.

Form 20-F X Form 40-F

Indicate by check mark whether the registrant byfurnishing the information contained in this Form is also thereby furnishing theinformation to the Commission pursuant to Rule 12g3-2(b) under the SecuritiesExchange Act of 1934

Yes No X

If "Yes" is marked, indicate below thefile number assigned to the registrant in connection with Rule 12g3-2(b):

Date 30 September 2003

BHP BILLITON HEALTH, SAFETY, ENVIRONMENT & COMMUNITY REPORT 2003

Please find attached the 2003 Health, Safety, Environment and Community Reportof the BHP Billiton Group. A more expansive, pdf version of that Report will beposted on the Groups website www.bhpbilliton.com.

Karen Wood Company Secretary

Our New Approach to Reporting

In early 2003, we commissioned an independentsurvey to find out in which formats ourstakeholders would prefer to receive our Health,Safety, Environment and Community (HSEC)Report.

The object of the exercise was to enable us toreport in a way that would allow stakeholders toquickly review our performance, while alsohaving the opportunity to easily access greateramounts of detail as required.

In response to this feedback, we are providingexpanded information on our website whilereducing our printed report to this smallersummary version. This is the mix preferred bythe great majority of our stakeholders. A briefsummary of our HSEC performance is also includedin the Companys Annual Report.

This printedSummary Report provides an overview of our HSECperformance. The adjacent diagram shows whereyou can access all the available information onthe website.

Global Reporting Initiative

The full HSEC Report on our website has beenprepared in accordance with the GlobalReporting Initiative (GRI)2002 SustainabilityReporting Guidelines. It should be recognisedthat, due to the size and complexity of ourbusiness, judgements have had to be maderegarding the extent of information that can bepresented in relation to each GRI indicator.Please contact the Company if you would likefurther information.

A GRI content index has been independentlyprepared by URS Corporate SustainableSolutions, outlining how each specificindicator of Part C of the GRI Guidelines hasbeen addressed.

Both the full HSEC Report andthe GRI index are available in PDF format.

About this Report

BHP Billiton is a Dual Listed Companycomprising BHP Billiton Limited and BHPBilliton Plc and their subsidiaries. The twoentities continue to exist as separatecompanies but operate as a combined groupknown as BHP Billiton.

Throughout this Report, the terms BHP Billiton,the Company and the Group refer to the combinedgroup. The statistics in this report cover thefacilities owned and operated by BHP Billitonduring the 12-month period to 30 June 2003.Joint venture projects where we are not theoperator are excluded unless expressly stated.The Report identifies where information has beenprovided to facilitate year-to-year comparisonof our performance without BHP Steel, whichcommenced trading on the Australian StockExchange as a separate listed company in July2002.

All dollar figures in the Report are US unless otherwise indicated.

For the full version of our Health, Safety,
Environment and Community Report 2003,
log onto www.bhpbilliton.com

4 Front cover main photo: Marcelino Melo Jr, Casthouse crew member, MozalAluminium Smelter, Mozambique
The supporting images reflect our journey towards sustainable development ourproducts, our people, our stakeholders, our future

Message from the Chief Executive Officer

4 Chip Goodyear, Chief Executive Officer

At BHP Billiton, we take a long-term view of ourbusiness. A key aspect of our strategicframework is our health, safety, environment andcommunity (HSEC)performance because we valueour people, we respect our host communities andwe believe that excellence in HSEC is good forour business.

I am very pleased to advise thatwe have made steady progress against many of thetargets in our HSEC scorecard. However, we alsorecognise that there is much work to be done,and this report outlines a number of our keywork programs.

While pleased about our achievements, I am deeplysaddened to report that three people lost theirlives in our controlled operations during theyear. These people lost their lives in the courseof earning a living and helping our operationsachieve their objectives. But none of ourachievements is worth the loss of a life, and wewill continue to seek opportunities to improveour safety performance and eliminate fatalitiesfrom the workplace.

Environmental performanceacross the company continued to be sound,reflecting our systematic approach to managingenvironmental risk. Management plans focusingupon driving eco-efficiency gains have beendeveloped in the areas of energy usage,greenhouse gas emissions, water and waste.

In line with our HSEC Policy, efforts havecontinued towards improving our engagement withour host communities. Our communitycontributions, supporting community programsand capacity building, this year amounted toUS$42million or 1.4 per cent of our pre-tax profit, which onceagain exceeded the target of 1 per cent. Inaddition, US$12.5billion was contributed toregional economies from expenditure associatedwith sustaining our operations.

During the year, we have been active in theInternational Council on Mining and Metals(ICMM)work program, contributing to theformulation of the Sustainable DevelopmentFramework, a guiding set of principles nowendorsed by all member companies. We have alsocommitted to implement the World Bank Guidelineson Involuntary Resettlement and the US-UKVoluntary Principles on Security and HumanRights.

We have been pleased over the past year toreceive external recognition of our performancein the areas of community partnerships,sustainable development and public reporting.Internally, our Employee HSEC Awards programhas been highly successful in recognisingexcellence in HSEC performance and transferringthose improvement ideas across theorganisation.

The full HSEC Report on ourwebsite has been prepared in accordance withthe Global Reporting Initiative 2002Sustainability Reporting Guidelines, andrepresents a balanced and reasonablepresentation of our organisations economic,environmental and social performance.

The leadership team at BHP Billiton is committedto our journey towards sustainable developmentand Zero Harm. We understand that our leadershipefforts are fundamental for success, and we willsupport and drive this relentlessly. Thisjourney, however, is not ours alone. It is allabout partnerships with our stakeholders ouremployees, contractors, shareholders, businesspartners, suppliers, customers, government andnon-government organisations and hostcommunities.

Together, we have the will, the resources andthe skills to be successful.

Chip Goodyear

Chief Executive Officer

HSEC Targets and Scorecard 2

HSEC Governance 4

Part of the Global Community 5

Performance Summaries 6

Auditors Verification Statement 15

Case Studies 16

Our Resources at Work 23

BHP Billiton Locations 24

BHP Billiton Employee HSEC Awards Program IBC

External Recognition (2002/03) IBC

BHP Billiton Charter BC

BHP Billiton HSEC Policy BC

About BHP Billiton BC

Contact Us BC

We are continuously improving our reportingsystems and endeavour to present useful andaccurate information. While every effort hasbeen made to ensure the accuracy of theinformation, including the figures, in thisReport, the data are derived from our manyoperations around the world and, in some cases,grouped data are not strictly comparable.

Anyone seeking to rely on information in thisReport or seeking to draw detailed conclusionsfrom the data should contact the Company forverification and assistance.

Your comments on the contents of our HSEC Reportwould be greatly appreciated. A Feedback Form isavailable as part of the full HSEC Report on ourwebsite at www.bhpbilliton.com

BHP Billiton Limited. ABN 49 004 028 077.
Registered in Australia. Registered Office (from 6 October 2003):
BHP Billiton Centre, 180 Lonsdale Street, Melbourne, Victoria 3000
Australia.

BHP Billiton Plc. Registration Number 3196209.
Registered in England and Wales. Registered Office:
Neathouse Place, London SW1V 1LH United Kingdom.

BHP BILLITON HSEC SUMMARY REPORT 2003 4 1

HSEC Targets and Scorecard

BHP Billiton HSEC Targets (Baseline 1 July 2001 to 30 June 2002)

Legend:= Targetexceeded or ahead of schedule= Targetachieved (> 95%) oron track = Target behind schedule = Target not achieved

MANAGEMENT SYSTEMS

All sites1 to undertake annual self-assessments against the BHPBilliton HSEC Management Standards. =

Systems in place and audits or self-assessments completedat 99 per cent of required sites in FY03. Audits were alsoconducted at three non-operated sites (not required bythe target).

All sites1 to achieveand maintain ISO 14001 Certification. =

All sites requiring ISO 14001 are accredited or have beenrecommended for accreditation by their ISO auditor.

Legal Compliance

Zero fines and prosecutions. =

Nine fines in FY03 totalling US$166 944.

Risk Management

Risk registers to be in place at all sites and within BHP Billitonbusinesses and Corporate. =

Risk registers in place at all required sites, and CustomerSector Group and Corporate levels. HSEC risk incorporatedin Enterprise-Wide Risk Management framework.

SAFETY

Zero fatalities =

Three fatalities in controlled activities.2

50 per cent reduction in Classified Injury Frequency Rate3(excluding First Aid treatments) at sites by 30 June 2007. =

20 per cent reduction in Classified Injury Frequency Ratein FY03.

HEALTH

All sites1 to implement a baseline survey on occupational exposurehazards and establish occupational hygiene monitoring andhealth surveillance programs. =

97 per cent of required sites implemented baseline surveys.In addition, 91 per cent of employees requiring medicalhealth surveillance completed the medical examination.

Annual reduction in percentage of people potentially exposedabove occupational exposure limits.4 =

FY03 was the baseline year in determining exposure data.

20 per cent reduction in incidence of occupational disease by30 June 2007. =

FY03 was the baseline year in determining incidence rates.

COMMUNITY

All sites5 to prepare public HSEC reports at a local level(including incidents, community complaints, and relevantsite-specific emissions) on an annual basis. =

HSEC reporting initiatives are in place at 97 per cent ofrequired sites or businesses.

All sites5 to have acommunity relations plan in place. =

Community relations plans in place at 95 per cent ofrequired sites and at 21 sites that were not required tomeet this target.

No transgressions within the Groups activities of the principlesembodied within the United Nations Universal Declaration ofHuman Rights. =

None reported.

Aggregate contribution to community programs, including in-kindsupport, of a target of 1 per cent pre-tax profits, calculatedon a three-year rolling average. =

Expenditure totalled US$42million, being 1.4 per cent ofpre-tax profits on a three-year rolling average.

2 4 BHP BILLITON HSEC SUMMARY REPORT 2003

BHP Billiton HSEC Targets (Baseline 1 July 2001 to 30 June 2002) continued

Legend:= Targetexceeded or ahead of schedule= Targetachieved (>95%) oron track = Target behind schedule = Target not achieved

ENVIRONMENT

Zero significant incidents (i.e., rated 3 and above on theBHP Billiton Consequence Severity Table). =

Zero significant environmental incidents.

Energy and Greenhouse

All sites with emissions greater than 100 000 tonnes per year ofcarbon dioxide equivalent6 are required to have energyconservation plans with specific targets in place. =

Energy conservation plans in place at 88 per cent ofrequired sites and at nine sites that were below theemissions threshold.

All sites with emissions greater than 100 000 tonnes per year ofcarbon dioxide equivalent 6 are required to have greenhouse gasmanagement programs. =

Greenhouse gas management programs in place at85 per cent of required sites and at eight sites thatwere below the emissions threshold.

Aggregate Group target for reduction in greenhouse gasemissions per unit of production of 5 per cent by 30 June 2007. =

FY03 intensity reduction achieved was 6 per cent, whichexceeded the long-range target (although data canfluctuate on an annual basis).

Water

All sites with fresh water consumption greater than 500 MLper annum7 to have water management plans in place. =

Water management plans in place at 98 per cent ofrequired sites and at 24 sites that were below thethreshold.

Aggregate Group target of 10 per cent reduction in fresh waterconsumption per unit of production by 30 June 2007. =

FY03 intensity reduction achieved was 1 per cent.

Waste

All sites1 to havewaste minimisation programs in place. =

Waste minimisation programs in place at 100 per cent ofrequired sites and at 18 sites that were not required tomeet this target.

Aggregate Group target of 20 per cent reduction in waste(excluding recycled and mining-related materials, such aswaste rock, tailings, coal reject and slag) per unit of productionby 30 June 2007. =

Increases in waste intensity reported in both general wasteand hazardous waste categories. The level of new projectdevelopment impacted the amount of general wastegenerated.

Land Management

All sites5 to have land management plans in place to protect andenhance agreed beneficial uses. =

Land management plans in place at 96 per cent ofrequired sites and at 21 sites that were not required tomeet this target.

Product Stewardship

Life cycle assessments prepared for all major BHP Billiton mineralsproducts by 30 June 2004 (incorporating participation in industryprograms as appropriate). =

This target is being monitored at the commodity leveland is on track.

Notes

1. Excludes exploration and development projects, sites being divested,closed sites and offices (numbering 57 sites in total).

2. Controlled activities are work-related activities where BHP Billitondirectly supervises and enforces HSEC standards.

3. A classified injury is any workplace injury that has resulted in theperson not returning to their unrestricted normal duties after the day onwhich the injury was received.

4. Target modified to reflect adoption of BHP Billiton exposure standards(see Health Performance Summary in the full HSEC Report).

5. Excludes petroleum platforms, exploration and development projects,closed sites, and offices with no significant community or land managementissues.

6. Forty sites have emissions greater than 100 000 tpa carbon dioxideequivalent and, combined, account for 98 per cent of the Groupsgreenhouse gas emissions.

7. Forty-one sites have freshwater consumption greater than 500 ML per annumand, combined, account for greater than 91 per cent of the Groupsconsumption.


HSEC Governance

Introduction

Clearly, strong governance in both the financialand non-financial arenas is a critical aspect ofrunning a successful corporation. Our approach tocorporate governance is outlined in our AnnualReport and on our website at www.bhpbilliton.com/bb/investorCentre/annualReports.jsp

This section outlines our approach to HSEC governance.

Structure and responsibilities

At every level of the organisation, our linemanagers, supported by functional personnel whoprovide specialist advice, are responsible forHSEC matters. Executive remuneration is directlylinked to the financial and non-financialperformance of the Company.

As shown in Figure 1, the Companys peak HSEgovernance body is the HSE Committee, which is asubcommittee of the Board. Further details onthe HSE Committee can be found on our website atwww.bhpbilliton.com/bb/aboutUs/governance.jsp

HSEC standards across the Company arecoordinated and monitored through the BHPBilliton Executive Committee.

The peakfunctional group is the HSEC Forum, which isinvolved in setting direction for the HSECfunction, identifying priority issues,monitoring HSEC performance and buildingconsensus for the way forward.

Figure 1. HSEC Organisation Structure

Policy, Standards and Systems

The Company has combined health, safety,environment and community matters in one policyand one set of management standards. TheStandards cover the entire life cycle of ourassets, from exploration through toconstruction, commissioning, operation,decommissioning, closure and rehabilitation. Wherever we operate, HSEC aspects are addressedin our decision-making processes, alongsideother business considerations. This means that,while we strive to deliver strong financialreturns to shareholders, we fully recognise anddeliver on our wider responsibilities to ourstakeholders.

The BHP Billiton Charter, HSEC Policy and HSECManagement Standards are mandatory at all oursites and operations, under a hierarchicalmanagement system where systems and documentsmust meet and support the requirements of thoseof higher levels, as shown in Figure 2. Where wehave no operational responsibility but have anequity stake or significant BHP Billiton assetsinvolved, the Standards are made available tothe operator so that comparable HSEC managementstandards can be applied. In addition, theStandards require operations to evaluate thesocial and environmental performance of ourcontractors andsuppliers.

Figure 2. Hierarchy of Systems and Documents

Our HSEC Management Standards include arequirement for an auditing process to ensurethat our Charter, HSEC Policy and Standards arebeing applied and to verify performance. Theaudit program is a triennial peer review process,with audit teams drawn from operations personnel,line management and external sources. During anyyear, those sites not audited complete aself-assessment against the Standards. Both theformal audits and self-assessments result in thedevelopment of performance improvement plans thatfacilitate progress to full compliance with theStandards. Conformance against the HSECManagement Standards is reported in the Audit andSelf-Assessment section on page 14.

The full HSEC Management Standards andperformance requirements are available onour website atwww.bhpbilliton.com/bbContentRepository/Policies/ HSECManagementStandardsIssue2.pdf

The HSEC Management Standards were revisedduring the year, resulting in a consolidated,yet more comprehensive, set of 15 standards. Thefollowing new documents have also been prepared:

Fatal Risk Control Protocols

Hearing Conservation Guidelines

Health Surveillance Guidelines

Health Exposure Assessment Guidelines

Energy and Greenhouse Guideline

Energy and Greenhouse Gas Management Plan Template

Human Rights Self-Assessment Toolkit.


Business conduct

The BHP Billiton Guide to BusinessConduct applies to all our employees andcontractors, regardless of their job orlocation.

The Guide seeks to providedirection and advice on conductingbusiness and interacting withgovernments, communities and businesspartners. It also states our position ona wide range of ethical issues, includingconflict of interest, financialinducements and bribery, insider tradingand political contributions. Managers andsupervisors are held accountable not onlyfor their own actions, but also for theactions of their staff.

Resolution of business conduct issues isencouraged at the local level. If thisis not possible, the issue can be raisedwith regional points of contact orhelplines based in southern Africa(Johannesburg), Europe (London),Australasia (Melbourne) and SouthAmerica (Tintaya, Peru). For issuesrelated to fraud or bribery, the FraudHotline is contacted. The final level ofmanagement review is the Global EthicsPanel.

4 The Guide to BusinessConduct is available on ourwebsite atwww.bhpbilliton.com/bb/peopleAndEmployment/globalBusinessConductGuide.jsp

Part of the Global Community

Our stakeholders

We are committed to maintaining andpromoting transparent dialogue withstakeholders in the resources industryand remaining responsive to the globalcommunitys concerns. We recognise theimportance of accountability tostakeholders and are aiming for a higherlevel of engagement and interaction,particularly with the communities inwhich we operate.

Our Charter, HSEC Policy, ManagementStandards and Guide to Business Conductall promote a commitment to acting withhonesty, integrity and fairness in ourinteractions with all our stakeholders.Maintaining comprehensive stakeholderrelationships is a critical part of ourjourney towards sustainable development.

Financial community

During the year, we continued toparticipate in key external benchmarkinginitiatives that attempt to measure BHPBillitons sustainable developmentperformance against others in oursector.

Over the period, we maintained ourinclusion in the UK FTSE4Good Index andour position in the Dow JonesSustainability Index. One of theleading proponents of sociallyresponsible investing, Storebrand inNorway, ranked us best in class forour environmental and socialperformance out of 21 companiesresearched.

Forum on Corporate Responsibility

The BHP Billiton Forum on CorporateResponsibility (FCR)brings togetherrepresentatives of our senior managementteam, the leaders of several keynon-government organisations andcommunity opinion leaders to discuss anddebate social and environmental mattersrelevant to the Company. Members of theFCR have an opportunity to provide adviceand to challengethe views of our senior management onbroader sustainable development issues.The Company is not bound by the adviceof the FCR, and the FCR does notnecessarily endorse the Companysdecisions.

Building global links

We are committed to proactive involvementin a number of initiatives to contributeto improving the sustainability of theindustry. Our individual businesses arealso actively engaged through theirsectoral organisations at national andinternational levels.

The major externally developed, voluntaryinitiatives1 that we are involved in orare progressively implementing include:

Australian Minerals IndustryCode for EnvironmentalManagement (1996)

Global Reporting Initiative (2002)

International Council onMining and Metals SustainableDevelopment Framework (2003)

ISO 14001 Environmental Management Systems (2002)

Mining Certification EvaluationProject Australian regionalinitiative (2002)

United Nations Global Compact(2002) (please refer to ourletter to the United Nations,included on our websitewww.bhpbilliton.com)

United Nations Universal Declaration of Human Rights (2001)

US-UK Voluntary Principles onSecurity and Human Rights (2003)

World Bank Guidelines on InvoluntaryResettlement (2003).

For furtherdetails, see the full HSEC Report onour website.

1. The date in brackets indicates theyear in which we commenced ourinvolvement or commitment.


Performance Summaries

The Companys performance in the areas of health, safety, environment andcommunity (HSEC)is driven by our commitmentto people, the environment, our host communities, and the pursuit ofoperational excellence to achieve great business outcomes for ourshareholders.

Figure 3 illustrates our Road to Zero Harm. This shows howthe things we do contribute towards creating a workplace where Zero Harm ispossible.

This section presents the key aspects of the Companys HSECperformance in 2002/03, with comments on performance trends and some of ourimprovement activities. During the period, the organisation was recognisedwith awards by external groups and organisations for its HSEC performance.These are summarised inside the back cover of this Report.

Figure 3. Road to Zero Harm


PERFORMANCE SUMMARIES

Health

4 Our operations provide personalprotective equipment as a measure toreduce potential exposure

Background

People are central to the success of ourbusiness. Accordingly, understanding thepotential for health risks andestablishing suitable mitigationmeasures are integral to our journeytowards Zero Harm.

Some of the potential health riskspresent in the organisation include:

inherent occupational health risksassociated with the nature of ouroperations, such as noise, dust,hazardous materials and gases andvibration

communicable diseasespresent in some of the countries inwhich we operate, including HIV/AIDS andmosquito-borne diseases

travel-relatedrisks

ergonomic exposures relating towork requirements

general suitabilityfor job criteria and fitness for work.

Performance

Establishing a baseline understanding ofpotential health exposures andperformance across the organisation wasa focus of our health programs duringthe year.

97 per cent of sites reportedundertaking a baseline survey onoccupational exposure hazards andestablishing associated monitoringprograms, 91 per cent of thoseemployees requiring medical healthsurveillance completed the medicalexamination.

Personal protective equipment(PPE)compliance in the Companywas, on average, 94 per cent. Thisis an area where we continuallyseek improvement and areencouraging operations to implementformal audit programs of PPEcompliance. Currently, 70 per cent ofoperations have formal audit programs.We will endeavour to increase this overthe coming year.

Key issues

Noise is the most significantoccupational exposure in our business,with 51 per cent of our employeespotentially exposed above the noiseexposure limit (85 dBA 8-hourtime-weighted average). Additionally,data indicate that, without the use ofPPE, 20 per cent of our site-basedemployees are potentially exposed tohazardous substances above action levels(50 per cent of the occupational exposurelimit) but below the occupationalexposure limit and 16 per cent ofemployees are potentially exposed abovethe occupational exposure limit. Theseemployees are protected from exposurethrough our PPE programs at every site.(See Figure 4.) While every effort ismade to protect all employees potentiallyexposed to any adverse health effectthrough the use of PPE, the drive is toprogressively reduce potential exposureover time.

Figure 4.

Percentage of Employees in Potential Exposures*
2002/03

*I.e., would be exposed if not wearing PPE.

During 2003, there were 226 new cases ofoccupational illnesses reportedthroughout the Company. While half ofthese were due to noise exposure, therewere also a significant number of newcases of respiratory disease andrepetitive trauma diagnosed. (See Figure5.)

Figure 5.

New Illnesses by Type
2002/03

The full year health reporting hasprovided comprehensive data thatindicate the extent to which we arepotentially exposing employees toworkplace hazards.

This requires that we continue to bevigilant in protecting employees fromthese exposures while we seek ways toreduce the exposure from our processesand work environments. The illness datacollected provide clear baselineinformation from which to measure thesuccess of our efforts to reduceexposure to harm and potentialdevelopment of illness.

Our health targets will ensure that wecontinue to look for opportunities through engineering, design and otherinitiatives to minimise the potentialadverse health effects associated withwork in our operations. (See Case Study,page 17.)



Safety

4 We are seeking to create a mindsetwhere people believe it is possible towork injury free

Background

The safety of our employees and thecommunities in which we operate is anintegral part of our business. Our goalis Zero Harm. To this end, we areseeking to create a mindset where peoplebelieve it is possible to work injuryfree regardless of where they are inthe world, what role they undertake orin which business they work. (See CaseStudies, page 18.)

Across theorganisation, we manage safety risksthrough our risk-based HSEC ManagementStandards and other dedicated systems.The key risks include:

mobileequipment and related interactions,including light vehicles and surface andunderground mobile equipment

underground ground control encompassingground stability and ground support

hazardous materials storage, handling,production, transport, recycling anddisposal

handling and processing ofmolten materials

plant and equipmentsafeguarding and isolation

working atheights.

Performance

In 2003, we saw a significantimprovement in our overall safetyperformance; however, we must remainvigilant.

We deeply regret that three peoplelost their lives in our controlledoperations during the year. Whilethis number of fatalities wassignificantly lower than last year(13), each death that occurs has aprofound impact on our people andtheir families. Our resolve toattain our goal of zero fatalitiesis stronger than ever, and we willrelentlessly pursue opportunities toachieve this. We are alsomonitoring, and have establishedprocesses to learn from, significantincidents (including fatalities)that result from activities relatedto our business but not directlywithin our management control (i.e.,not at controlled operations). Therewere 16 fatalities within thiscategory during the reportingperiod. (The Company broadly alignsreporting criteria with the USOccupational Safety and HealthAdministration Standards.) Figure 6presents fatalities at controlledoperations from 2000/01 to 2002/03.

We received five health andsafety related fines totallingUS$129 372. These are detailedin our full HSEC Report.

A 20 per cent reduction in ourClassified Injury Frequency Ratefrom 6.51 in 2001/02 to 5.18 in2002/03, was a promising achievementduring the period, reflectingeffortsdedicated to safety improvement. (SeeFigure 7.) A classified injury is anyworkplace injury that has resulted inthe person not returning to theirunrestricted normal duties after the dayon which the injury was received.

Figure 6.

Fatalities (controlled operations)
2000/01 to 2002/03

Figure 7.

Classified Injury Frequency Rate*
2001/02 to 2002/03

The Classified InjuryFrequency Rate was introduced asa measure in the 2001/02reporting period. The 2001/02Lost Time Injury Frequency Ratewas 2.24.

Key issues

Our strategies for safety improvementfocus on people and systems, withemphasis on:

leadership effectiveness

behaviours and awareness

rigorousstandards and procedures for managingkey risks.

A significant step we havetaken to support our drive to eliminatefatalities from our operations is thedevelopment of Fatal Risk ControlProtocols in nine key areas. (See CaseStudy, page 18.) The Protocols werewritten by experienced teams drawn fromacross the Company.

This initiative followed a review of ourfatal and high potential incidents overthe last ten years, from which weidentified a number of common risks toour people risks that require thedevelopment of sound practices toeliminate incidents that have thepotential to cause fatalities.


Safety continued

Figure 8 provides an analysis of thefatal and high potential incidents bycause for the 2002/03 period.

Figure 8.

Significant Incidents
by Cause
2002/03

The Fatal Risk Control Protocols cover the following nine areas:

Light Vehicles

Surface Mobile Equipment

Underground Mobile Equipment

Underground Ground Control

Hazardous Materials Management

Molten Materials Management

Equipment Safeguarding

Isolation

Working at Heights.

These Protocols are mandatory at allour controlled sites and operations.They establish minimum performanceexpectations for managing risk in eachof the nine areas.

The safety improvement road map (Figure9) is our guide to safety excellence.The diagram illustrates how, as thematurity of our organisation increases,our safety improvement initiativesbecome all encompassing. The most matureorganisations understand that thebehaviours of their people are the keyto their success.

Figure 9.

Safety Improvement Road Map

Environment

4 We are focusing on increasing our understanding of environmental issues

Background

BHP Billiton owns and operates a diverserange of businesses in differentcountries and ecosystems around theworld. These businesses, by theirnature, have the potential to affect theenvironment.

Potential significant environmentalimpacts that we manage through ourHSEC Management Standards, HSEC riskassessment and management programs andother dedicated systems include:

greenhouse gas and other gaseousemissions

reductions in water quality

impacts on land associated with landdisturbance

alterations tobiodiversity, either directly orindirectly as a result of ouroperations

indirect impactsencompassing any of the above as aresult of the products and services wepurchase, lease or provide.(See Case Studies, pages 19 and 20.)

BHP BILLITON HSEC SUMMARY REPORT 20034 9


Environment continued

Performance

Our focus for the past year has been ona number of fronts:working to establish environmentalmanagement systems and eco-efficiencyplans at sites; increasing ourunderstanding and refining ourapproaches to issues such as climatechange, biodiversity and eco-efficiency;and improving our Company-wideenvironmental information systems totrack performance.

A summary of ourenvironmental performance is presentedin Figure 10. Performance aspects ofnote include the following.

All of the sites requiring ISO14001 certification of theirEnvironmental Management Systemseither received or were notifiedthat they had been recommended forcertification.

Environmental management plans(with reduction targets aimed atdriving eco-efficiencies) for landmanagement, water use and wastemanagement have been establishedat over 95 per cent of requiredsites. Greenhouse gas managementprograms have been developed at 85per cent of required sites, andenergy conservation programs at 88per cent of required sites.

No significant environmentalincidents (level 3 or above in theBHP Billiton Consequence SeverityTable) occurred.

Environmental fines during thereporting period totalled US$37 572,details of which are included in ourfull HSEC Report.

Environmental spending for thereporting period was US$134million,which includes costs forrehabilitation, remediation,environmental monitoring,environmental research anddevelopment and otherenvironment-related activities.These costs exclude expenditureassociated with the operation andmaintenance of pollution controlequipment and the like.

Financial provisions for siteclosure, rehabilitation andremediation activities according toUnited Kingdom Generally AcceptedAccounting Principles (UK GAAP)amounted to US$2025million.

Key issues
Resource use
Land

At 30 June 2003, land newly disturbedwas 3540 hectares compared to 4520hectares for the previous year. Thereason there was less newly disturbedland was primarily a result of ouropen-cut Queensland coal operations notneeding to disturb any further land formining during the year. The arearehabilitated was 1790 hectares, aslight decrease from 2230 hectares lastyear. (See Figure 11.)

Total land requiring rehabilitationreduced from 82 910 hectares to 77 160hectares, mainly due to a clarificationof the estimate of land requiringrehabilitation at our Escondidaoperations from the previous year.

Accidental discharges of hydrocarbons toland and water totalled 104 600 litresduring the reporting period. This totalconsisted of a number of small-volumespills, including hydrocarbons releasedfrom primary containment facilities butcaptured in secondary containmentfacilities.

Figure 10. Summary of Environmental Performance 1999/00 to 2002/03 1

Unit 1999/00 2000/01 2001/02 2002/03

Land Use

Land disturbed Hectares 4170 4930 4520 3 540

Land rehabilitated Hectares 2 090 2 120 2 230 1 790

Land requiring rehabilitation 2 Hectares 77 770 81 320 82 910 77 160

Resource Consumption

Fresh water Megalitres 154 000 160 300 147 100 132 630

Recycled water 3 Megalitres 64 100 99 700 543 000 175 350

Energy Petajoules 382 390 396 292

Waste Disposal 4

Hazardous waste Tonnes 103 900 93 800 80 700 79 940

General waste to landfill Tonnes 288 700 213 700 107 400 115 280

Air Emissions

Oxides of sulphur (SOx) 5 Tonnes 78 500 89 900 56 330 50 020

Oxides of nitrogen (NOx) 5 Tonnes 118 600 112 300 55 750 49 640

Fluoride Tonnes 1 713 1 795 1 680 910

Greenhouse gases 6 Tonnes CO2-e 62600000 57100000 60020000 47070000

1. In the summary text of each performance category, information has beenprovided to facilitate year-to-year comparison of performance without BHPSteel.

2. Rehabilitation requirements assuming immediate closure of all operations.Escondida re-estimated its land area requiring rehabilitation in 2002/03.

3. Recycled water: Not all sites reported recycled water in 1999/00 and2000/01.

4. Waste: Excludes recycled materials and mining-related materials such aswaste rock, tailings, coal reject and slag.

5. Transport and logistics operations were divested during 2001/02.

6. Greenhouse gases (1999/00 and 2000/01): Different methodologies ofreporting were used prior to the BHP Billiton merger.



Energy

Total energy consumption was 292petajoules, a decrease from 396petajoules last year. This was primarilydue to the demerger of BHP Steel, whichcontributed 131 petajoules in 2001/02.While energy consumption rose during theyear due to production increases at anumber of our operations, this waspartially offset by improvements at ourmanganese and chrome operations, andinitiatives in improving energyefficiency such as the Energy SmartProgram at our EKATI Diamond Mine. (SeeCase Study, page 19.) The trend for theCompany is shown in Figure 12.

Figure 12.
Total Energy Use
1999/00 to 2002/03

The major sources of energy use arefrom purchased electricity, naturalgas, and coal and coke, as shown inFigure 13.

Figure 13.
Energy Use by Type
2002/03

The overall energy intensity index1 forthe Company is illustrated in Figure 14.

Figure 14.
BHP Billiton
Overall Energy Intensity
2001/02 to 2002/03

Water

Availability of fresh water is animportant global environmental issue.

Total fresh water consumption for thereporting period was 132 630megalitres, a decrease from lastyears total of 147 100 megalitres.Recycled water reduced from 543 000megalitres in the previous reportingperiod to 175 350 megalitres. The reduction in theamount of fresh water consumed and waterrecycled was mainly due to the demergerof BHP Steel, which consumed 26 300megalitres of fresh water and recycled415 600 megalitres of water in 2001/02.

Figure 15 presents the water consumption for the Company.

The overall fresh water intensity index1 is presented in Figure 16.

Figure 16.
BHP Billiton
Overall Fresh Water Intensity
2001/02 to 2002/03

Gaseous emissions
Greenhouse gas emissions

Our greenhouse gas emissions for theyear totalled 47.1million tonnes ofcarbon dioxide equivalent (CO2-e), areduction from last years 60.0milliontonnes of CO2 equivalent. The primaryfactor in the reduction of emissionswas the demerger of BHP Steel, whichcontributed 13.4million tonnes of CO2equivalent in 2001/02.

Greenhouse gas emissions for the pastfour years are presented in Figure 17.

Figure 17.
Greenhouse Gas Emissions
1999/00 to 2002/03

1. The Intensity Index has been developed as a Company-wide performanceindicator on environmental aspects such as energy use, greenhouse gasemissions and fresh water consumption. The index concept allowsperformance from different business groups or sites, all of which may havedifferent operating conditions and product mixes, to be added together toform an overall indicator per unit of production. The baseline for theIntensity Indices is 2001/02 and, as such, has a value of 100.




The sources of greenhouse gas emissions are presented in Figure 18.

Figure 18.

Sources of Greenhouse Gas Emissions 2002/03

The overall greenhouse gas intensityindex1 forthe Company is presented in Figure 19. Theintensity reduction achieved for the year was 6per cent, however it should be noted that datacan fluctuate on an annual basis.

Figure 19.

BHP Billiton Overall Greenhouse Gas Intensity 2001/02 to 2002/03

Oxides of sulphur and nitrogen

Oxides of nitrogen (NOx) emissions for thereporting period were 49 640 tonnes, compared to55 750 tonnes last year. Oxides of sulphur (SOx)emissions totalled 50 020 tonnes, compared to 56330 tonnes last year. The Companys overallperformance for NOx and SOx are presented inFigure 20 and Figure 21 respectively.

Thereduction in NOx and SOx emissions is mainly dueto the demerger of BHP Steel. The purchase ofdiesel with low sulphur content by our sitesalso contributed to the reduction of SOx.

Figure 20.

NOx Emissions to Air 1999/00 to 2002/03

Figure 21.

SOx Emissions to Air 1999/00 to 2002/03

Fluoride

There was a significant decrease in fluorideemissions, from 1680 tonnes last year to 910tonnes this year. This was due to substantialimprovements in emission control at ouraluminium smelters, including the environmentalupgrade of potrooms B and C at Bayside, SouthAfrica. The Companys fluoride emissions arepresented in Figure 22.

Figure 22.

Fluoride Emissions to Air 1999/00 to 2002/03

Waste

Total general waste (consisting of domestic andconstruction wastes) disposed of to landfillduring the reporting period was 115 280 tonnes,an increase against the previous years total of107 400 tonnes. The increase was mainly due toconstruction associated with expansionactivities at some of our sites.

Hazardous waste (excluding recycled materials, overburden,tailings and slags) generated in the reportingperiod was 79 940 tonnes. This consistedprimarily of waste oil, chemical wastes,hazardous baghouse dusts and other hydrocarbonwastes.

Indicative trends of waste disposed ofby the Company are presented in Figure 23.

Figure 23.

Waste Disposal 1999/00 to 2002/03

Biodiversity

Biodiversity initiatives were undertaken in anumber of areas over the past year. We haveassessed each of our sites to determine whetherany of our operations are within protectivecategories I to IV of the World ConservationUnion, formerly the International Union for theConservation of Nature (IUCN). We have severalsites adjacent to protected areas; and theMinerva natural gas project, which has beengiven full authorisation, has horizontallydrilled underneath the Port Campbell NationalPark in Victoria, Australia (Category IINational Park Recreation).

Through the ICMM, wealso actively participate with other interestedorganisations in a joint program of work in thearea of mining and biodiversity, includingdevelopment of principles and related reportingcriteria. As an ICMM member company, we haveundertaken not to explore or develop mines inWorld Heritage Properties.

1. The Intensity Index has been developed as a Company-wide performanceindicator on environmental aspects such as energy use, greenhouse gasemissions and fresh water consumption. The index concept allowsperformance from different business groups or sites, all of which may havedifferent operating conditions and product mixes, to be added together toform an overall indicator per unit of production. The baseline for theIntensity Indices is 2001/02 and, as such, has a value of 100.



Climate change

We are working on activities related toclimate change in a number of ways.

In addition to our 5 per cent greenhouse gasintensity reduction target, we are committed toworking with customers to improve energyefficiency in the downstream consumption of ourEnergy Coal products. We are assessingopportunities to use the Kyoto Protocols CleanDevelopment Mechanism to reduce emissions andpromote sustainable development. Carbon pricingsensitivity analysis is considered in ourdecisions for new projects and investments thatwould emit more than 100 000 tonnes of CO2equivalent per year. We are also funding researchinto geological sequestration of CO2 and thedevelopment of low-emission coal technologies.

Product stewardship

During the year, we continued our work andparticipation in product stewardshipactivities. For example, our Base MetalsCustomer Sector Group (CSG)is conductingLife Cycle Assessment studies for copper inconjunction with the International CopperAssociation and for zinc with theInternational Zinc Association. Additionally,they are taking a primary role in the effortson lead stewardship through their involvementin the Green Lead project.

Our Stainless Steel Materials CSG has completeda Life Cycle Assessment with the NickelDevelopment Institute. Our manganese business,in association with research institutes anduniversities, has embarked on an initiative topromote a selenium-free manganese product andour Australian coal businesses have participatedin the Australian Coal Association ResearchProgram project, Coal in a SustainableSociety.

Community

4 We recognise the importance ofassisting in the development of communitieswherever we operate

Background

The Company owns and operates a diverse range ofbusinesses in different countries and culturesaround the world. We track a range of socialissues relevant to sustainable development,including:

human rights of our employees,contractors, suppliers, and the communities inwhich we operate

community development (SeeCase Study, page 21.)

indigenous communitiesthat own the land impacted by our operations orlive nearby

ethics and business conduct

indirect social impacts incorporating issuessuch as community dependency on our activities.

Performance

During the year, our community performancecontinued to progress well on a number offronts:

Total community contributions of US$42million equated to 1.4 per cent of pre-taxprofit (three-year rolling average), whichexceeded our target of 1 per cent. Thisamount includes our contribution tocommunity programs at joint ventureoperations. The main areas of focus forcommunity programs were community welfare(31 per cent) and education (29 per cent).(See Figure 24.)

Figure 24.

Contributions to Community Programs by Category 2002/03

97 per cent of our sites have producedpublic HSEC reports, which meets ourtarget. These reports are available on ourwebsite atwww.bhpbilliton.com/bb/sustainableDevelopment/operationsHSECReports.jsp

95 per cent of our sites have communityrelations plans in place or were covered bya regional development plan developed bythe business group. Complaints werereceived by 62 per cent of our sites. Ofthe 361 complaints, 22 per cent wererelated to dust, 22 per cent to noise and17 per cent to odour.

There were 55 substantive calls to theBusiness Conduct Helpline and FraudHotline. A breakdown of these calls isincluded in Figure 25. Several casesrequired involvement of the Global EthicsPanel.

Figure 25.

Business Conduct Helpline and Fraud Hotline Categories of Calls 2002/03

Key issues

During the period, we adopted the World BankGuidelines on Involuntary Resettlement and theUS-UK Voluntary Principles on Security and HumanRights, so that our policies and systems are inline with the International Council on Miningand Metals Sustainable Development Frameworkand key stakeholder expectations. (See CaseStudy, page 21.)

4 BHP BILLITON HSEC SUMMARY REPORT 2003 13


Community continued

A new employee Matched Giving Program waspiloted in South Africa, the United Kingdom andAustralia. The program aims to strengthen localcommunities by supporting and encouragingemployees who volunteer, fundraise or donate tonot-for-profit organisations.

The pilot Matched Giving Program was wellreceived, with over US$300 000 being contributedto 274 not-for-profit organisations. For example,more than 36 000 hours in personal volunteeringwere matched with cash donations to organisationswhere the employees offered their time.

In conjunction with Oxfam Community Aid Abroad,we ran the second Corporate Community LeadershipProgram in Orissa, India. With the aim ofincreasing understanding of social issuesrelating to our operations, the program involved12 employees from across our businesses.

Employee Relations

Employee profile

The average number of permanent employees acrossthe Company (including BHP Billitons owned andoperated facilities and share of unincorporatedjoint ventures) was 34 800, compared to 51 000reported in the previous period. A regionalbreakdown of employees is presented in Figure 26.The demerger of BHP Steel accounted for areduction in employees of 12 270, with the saleof transport and logistics businesses accountingfor another 1380. About 98 per cent of employeesat operated sites or corporate offices workfull-time. The average turnover rate of employeesat operated sites and corporate offices was 5 percent. A total of about 32 000 contractors wereemployed at operated sites.

Figure 26.

Regional Geographic Breakdown of Total Number of Employees 2002/03

All sites report the age of their youngestworker and the corresponding minimum workingage in their jurisdiction. The youngestemployees were 17years of age. All Companyemployees earned greater than the stipulatedminimum wage in the countries in which theyworked.

Freedom of association

While fully recognising the right of ouremployees to freely associate and join tradeunions, we have a number of sites wherewe have a mix of collective and individualarrangements. Prospective employees are madeaware of employment arrangements prior tojoining the Company. A total of 22 400employees, or about 60 per cent of theworkforce, were covered by collective bargainingagreements at operated sites and offices. TheCompany has a policy to consult with employeeson major organisational changes.

Diversity

The Company is committed to developing a diverseworkforce and to providing a work environment inwhich everyone is treated fairly and withrespect. Harassment of any form is unacceptable.An example of the ongoing policies or programswe undertake to address employment diversityissues is our Employment Equity Policy in SouthAfrica, which ultimately aims to achieverepresentation at all levels in our businessesconsistent with the demographic profile of SouthAfrica. (See Case Study, page 22.)

In the yearending June 2003, about 8 per cent of full-timeemployees at operated sites/offices were women.

Human rights

During the year, a Human Rights Self-AssessmentToolkit was developed and distributed to allCompany sites to assist them in appraising theirpotential exposure to human rights issues. Theself-assessment will form part of the HSEC auditprocess.

Three sites reported human rightsissues during the year. At the Tintaya coppermine in Peru, pending issues are being addressedby the Mesa de Dialogo, a dialogue processestablished with representation from the fivecommunities in the Espinar region. Two issues inSouth Africa are currently being resolved. Onerelates to squatters dwelling on a mine propertyand the other to the voluntary relocation of aperson living in a house on a closed mine site.

Indigenous employment and training

Indigenous employment is an important issue ata number of our sites. Some sites have setspecific targets for indigenous employment andare publicly reporting their progress againstthese targets.

Indigenous employment strategies are in operationat Iron Ore, Western Australia and Groote EylandtMining Company (GEMCO), Northern Territory inAustralia; New Mexico Coal in the US; and EKATIDiamond Mine in Canada. In addition, many sitesoperate training programs to increase proficiencyin general literacy or technical skills. (See ourfull HSEC Report on the website.)

Audit and Self-Assessment

A total of 34 HSEC audits were conducted duringthe year to assess the level of implementationof the HSEC Management Standards. The auditprogram involved 99 personnel from both HSECfunctional roles and operational roles (13 ofwhom participated in audits last year) andeight external auditors (two of whom aremembers of the HSE Committee of the BHPBilliton Board).

The average overall conformance to theManagement Standards based on the sites auditedis 3.4 out of 5. Sites not audited during theyear were required to undertake self-assessmentsagainst the Standards. The results from these 51self-assessments have been combined with theaudit results to give an overall conformance of3.6 out of 5 for the organisation.

14 HSEC SUMMARY REPORT 2003

Economic

The data in this section deal with the economicaffairs of the BHP Billiton Group. The Companyhas an annual turnover of US$17.5billion, and anenterprise value of US$35billion (30 June 2003).The Companys diversification by operating assetsacross geographic regions is illustrated inFigure 27.

Figure 27.

Diversification by Geographic Region (Net Operating Assets) At 30 June 2003

Our shareholder base is widely diversified,with approximately 39 per cent of shares heldin Australia, 30 per cent in Europe, 18 percent in North America, 8 per cent in SouthAfrica and 5 per cent in Asia.

Globally, the Company spent in the order ofUS$12.5billion sustaining its businesses.The breakdown of this figure by category isshown in Figure 28.

Figure 28.

Total Allocated Expenditure by Category 2002/03 (US$million)

Figure 29 shows these data broken down byregion. This section helps to quantify theregional economic contributions of the Group.

We have confirmed our support for the ExtractiveIndustries Transparency Initiative regardingdisclosure of payment of taxes and royalties. Wewill work with our host governments thatparticipate in this process to ensure publicreporting of these payments. In the interim, wehave presented these data on a regional basis inFigure 29.

Figure 29.

Expenditure by region(US$million)1 2002/03

Income Tax Employee Payments

Resource Rent Tax Goods and Community Shareholder Regional

and Royalties Services 2

Contributions 4 Dividends 3 Totals

Africa 317 2036 14 72 2439

Australia and Asia 1241 5061 10 396 6 708

Europe 89 207 < 1 270 567

North America 95 913 5 162 1 175

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