Steps to Safe Hot Work and Confined Space Entry | Health and Safety

This article demonstrates the standard procedures and good practices for the safe execution of hot work as well as in confined working areas and has the purpose of eliminating the danger of fires or gas ignitions during the execution of hot work. 

Eliminating the likelihood of workers being overcome by hazardous fumes and gases as well as a lack of oxygen whilst working in confined spaces, appropriately managing and minimizing risks associated with working in confined spaces and execution of hot work. 

This article includes an introduction, definitions-steps to safe hot work execution and confined space entry. 

Fires in the workplace and confined space-related accidents are often devastating and can result in loss of life, serious injury and major business disturbances. It must, therefore, be eliminated at all costs first and foremost. Let us define some of the concepts and terminology hot work is any work that requires the use of an open flame or spark-producing apparatus, it includes but is not limited to welding, cutting, gouging, burning, grinding, lancing or any heat-producing tasks that could ignite combustible materials or flammable atmospheres. 

Confined space is defined as areas that are large enough and so configured that a person can bodily enter and perform assigned work, is not designed for continuous people occupancy, is not exposed to natural ventilation contains or has the potential to contain hazardous atmosphere such as gases or vapors, contains a material that has the potential to engulf an entrant contains any other recognized safety or health hazards such as unguarded machinery, exposed live electrical wires or heat stress, have walls that converge inward or floors that sloped downward and taper into a smaller area which could trap or asphyxiate an entrant has limited or restricted means of entry or exit, for example- tanks, vessels, silos, storage bins, trenches and sumps deeper than 2 meters, pipelines, dragline tubs, and revolving frame compartments. Hot work and confined space entry permits are two different written or printed documents, permits issued by permit issuer, this authorizes safe entry into confined spaces and specified hot work at specific locations and time periods, the oxygen-deficient atmosphere is an atmosphere containing less than 19.5% oxygen by volume. 

The hazardous atmosphere is an atmosphere that may expose individuals to the risk of death, incapacitation impairment of the ability to self-rescue, injury or acute illness. Acceptable entry conditions are conditions that have got to exist during a permit space to permit entry and to make sure that individuals involved a permit required confined space entry can safely enter into and work within the space the five steps to safe hot work execution and confined space entry are mandatory procedural requirements authorizing hot work execution and confined space entry preparing for Hot work execution and confined space entry executing hot work and perform work in confined spaces and post hot work and confined space entry requirements mandatory procedural requirements the engineering manager is responsible for the following mandatory procedural requirements register of all identify confined spaces per plant or area including category and classification. 

Confined spaces will be clearly identified with appropriate signage. Confined space and hot work procedures and planned task observations, risk assessments per individual confined space or class personnel list with competency to issue clearance certificates identification of work requirements i.e.- hot work cleaning and purging of confined spaces confined space entry permits and registers hot work permits and registers procedure to disable and restore fire protection systems during scheduled outages or breakdowns emergency evacuation and rescue procedure emergency rescue equipment and training certificates isolation and lockout procedure and register atmospheric testing and sampling equipment certificates and training records tools and equipment logbooks authorizing hot work execution and confined space entry authorization to execute hot work and to enter confined spaces include training appointments risk assessments hot work and confined space entry permits only persons that are trained qualified competent and fit to perform their duties will be allowed to execute hot work and enter confined spaces grinders must also be declared competent this training ensures that individuals are equipped with the skills and knowledge to understand the hazards associated with hot work working in confined spaces the contents of permits and the control measures implemented for their protection which includes emergency procedures. 

All Hot work operators must attend attaining presentation have passed the Hot work assessment and plan task observation before being appointed and authorized by the responsible section engineer a thorough formal risk assessment is required to identify all hazards to assess potential loss events and to identify the required barriers risk assessments are to be reviewed whenever processes people or circumstances change identified energies include potential kinetic thermal chemical acoustic vibrating energies these energies could lead to the following significant risks death by suffocation fire or explosion slack of oxygen claustrophobia burns inundation of fluid engulfment or drowning toxic fumes or substances insect and/or snake lights buried under materials such as mud coal or rock electrocution permit systems are intended to ensure that individuals involved with hot work or who have to enter confined spaces are aware of the Associated hazards and that control measures are implemented to mitigate the risks. the permit system provides a step-by-step checklist and reminds workers of the required legislation safety precautions and responsibilities before during and after task executions, it also enables you to keep track of hot work and confined space entry activities and ensures that these activities are being conducted safely a permit to work and to enter confined spaces is issued with authorization by a responsible person in charge of the work to be carried out it is important to note that permits expire after 24 hours. 

Hot work operations are strictly prohibited under the following conditions in areas where a hot work permit is required but not obtained in the areas where a sprinkler or other fire suppression system is activated in the presence of explosive atmospheres such as mixture of flammable gases vapors liquids all dust in areas near to the storage of large quantities of flammable or combustible materials that can readily ignite on any rim or components onto which a tire is fitted preparing for Hut work execution and confined space entry preparation to execute hot work and to enter confined spaces includes isolation and lockout emergency response plan correct personal protective equipment. Equipment inspections confined space entry control continuous risk assessment slam deactivate automatic fire suppression system barricade areas make safe confined spaces. 

All sources of energy that might have a direct or indirect influence on the health and safety of persons in the confined space, all working area must be isolated and locked out at the source by a responsible person as per the isolation fatal risk standard and procedures before commencement of any work, the keys are placed inside a lockable key cabinet, every person locks the key cabinet with his own personal lock and fills in the lockout register with his personal details. 

The isolation procedure has further been established to prevent the introduction of contaminants or conditions through piping, ducts, vents, drains, conveyors, service pipes etc. The activation or energizing of machinery inside and outside the confined space that could adversely affect the space. 

The release of any stored energy or potential energy in the plant, tools and equipment an emergency response plan that was developed from a review of potential emergency scenarios must be in place and discussed before commencement of any work. 

When things fail during a confined space people could also be exposed to serious and immediate danger therefore effective arrangements for raising the alarm and completing rescue operations in an emergency are essential ensure that there is additional fire suppression equipment available in the case of emergency such as a fire tender on-site during shutdowns another best practice is the commonly known dedicated position for fire extinguishers at a dragline shutdown additional fire extinguishers are positioned on the ground both sides of a drag line next to the walking shoes and on deck at both sides of the machinery house the shutdown site layout plan also clearly identifies position of all emergency response equipment the correct Personal Protective Equipment also known as PPE and respiratory protective equipment RPE as defined by the risk assessment and minimum site requirement shall be used and maintained in a sanitary and reliable condition. 

PPE is issued against individuals names the scanning system provides accurate history and effectively controls cost minimum PPE site requirements for hot work execution include safety shoes long leather spats/ safety shoes with overall worn over the spats please take note that nylon type overalls or jackets are not allowed long leather gloves leather apron dust mask earplugs fire resistant skullcap with neck flap face shield with goggles or welding helmet Lansing suit for Lansing activities the supervisor issuing the permit to work is responsible for the inspection and signing of equipment logbooks the check for gas equipment leakage damage to electrical and welding Gables and special attention is given to welding tongue hand grips the supervisor further checks that all welding cutting and ventilation equipment is safe to use and signs off equipment logbooks minimum required safety equipment includes calibrated atmospheric testing equipment that can also measure monitor and alarm on flammable and hazardous gas, oxygen deficiency and carbon monoxide exposure adequate fire extinguishing equipment, effective means of communication to link the person in confined space or executing hot work with a spotter first aid equipment, PPE are suitable for the specific task.

Barricades and no smoking signs portable lighting where required any other safety equipment identified by the risk assessment force ventilation equipment where required a lifeline is strongly recommended naked flame lighter such as matches or cigarette lighters are not permitted and only friction type lighters shall be used furthermore only approved lights are to be used in confined spaces before work commences workers execute a - and equipment pre use inspection entrances to confined spaces will be padlocked dwell and appropriate signs displayed before work commences in confined spaces signs are erected at all entrances to prevent entry of persons not involved in the work and who do not have the required permit to enter. people with valid confined space entry permits complete the confined space entry register a good entry control practice used by the dragline shutdown team is a magnetic sticker system where individuals placed a magnetic nametag on a board at the site office as well as at the point of entry this system allows easy monitoring of people inside the confined space at any point in time slam stands for stop look assess and manage people stop and take a few minutes to think about the tasks at hand they look around and identify potential hazards questions are raised. 

Do we have the correct tools and are they safe to use how safe is our working area they assess the level of risk for the identified hazards and more questions are raised could something go wrong today what could happen to me and the others they all commit to the required actions to manage risk appropriately in order to prevent injury or damage to equipment the supervisor also ensures that workers do not suffer from claustrophobia before entering confined spaces a responsible person signs the automatic fire suppression register and deactivates the systems before the execution of any hot work to avoid accidental discharge of systems that might lead to lack of oxygen and result in suffocation on completion of all work the responsible person reactivates the automatic fire suppression systems and signs the register to confirm that fire protection systems are restored and reliable working areas are barricaded in such a way that there is no direct or indirect risk to the health and safety of personnel nearby personnel must also be suitably protected against heat Sparks slag etc. a spotter is required to ensure that people do not enter barricaded areas where hot work is being done especially in the case of hot work overhead barricades carrying no smoking signs are required at every confined space entry in the making safe of confined spaces various means might be employed such as force ventilation flushing with water neutralizing harmful chemicals etc. 

All covers and manholes must also be open at least 30 minutes prior to entry carefully check the side of the manholes tanks and reservoirs remove all loose material to safeguard persons inside from falling objects access points must be kept free of any obstructions such as leads hoses ventilation ducts etc. when toxic fumes of gases may be present like in sewer manholes, a competent person fully equipped with the appropriate respiratory equipment is to ensure the presence of sufficient oxygen to sustain life by carrying out atmospheric tests it is vitally important to test for methane carbon monoxide and oxygen deficiency prior to entering holes all sums acceptable entry conditions must first be achieved before entry to confined space can be permitted the air we breathe normally contains 21 % oxygen by volume although oxygen levels of 19.5%-23.5% by volume is considered to be safe.

Some situations can cause the level of oxygen to dramatically decrease leading to an oxygen-deficient atmosphere, therefore, testing for these hazardous substances need to continue during the operation by the supervisor, too much oxygen may also pose a risk to health and safety. Oxygen-enriched atmosphere can increase the risk of fire or explosion. Hot work and painting and confined spaces will only be permitted if the confined spaces are constantly ventilated by air blower or extractor fans to achieve a minimum air velocity of 0.5 m/s. Adequate firefighting equipment must be on hand and in good condition to contain and putout any fire that may occur within the working area, beware of snakes, spiders, scorpions or any other insects when entering trenches and confined spaces. All combustible and flammable material must be removed and working areas appropriately level and where combustible and flammable material cannot be removed it must be wet down or covered with a non-combustible material or cover any exposed equipment such as gearing open shafts gear cases motors electrical panels etc. must be covered with a fire resistant cover to prevent any damage during hot work execution. 

Consider and take the necessary precaution to avoid damage to equipment caused by heat that is generated by the hot work. Ensure that gas cylinders are secured in an upright position away from any heat source to avoid gas explosions, Welding, preheating, propane torches are not permitted in dragline tubs and revolving frames controlled pre heating systems drastically reduce risk and provide a more effective heat control with printout records. Executing hot work and perform work in confined spaces, the following safety precautions shall be adhered to during hot work executions and performing work in confined spaces. Permit, checklists, communication, standby person, frequent atmospheric tests, spotters, fire hazard free conditions. We assess risk and restore safety conditions workers confirm that all items on the hot work and confined space entry. Permit checklists are complied with and signed off a communication system is established to enable communication between people inside and outside the confined space, especially to someone help in emergency communication, can be achieved by radio, hand signals or other suitable methods. Good continuous communication must be maintained with the spotter during hot work execution. 

All confined space entry a standby person is assigned to continuously monitor the well-being of those inside the confined space the standby person with the authority to order people to exit the space in any hazardous situation will raise the alarm and should never enter the confined space to attempt rescue. Persons inside confined spaces must be withdrawn immediately when the presence of methane, carbon monoxide or oxygen deficiency is detected. Testing and monitoring the atmosphere in confined spaces by a competent person using a suitable correctly calibrated gas detector is a routine part of determining appropriate risk control. Atmosphere tests must be done in different levels top, middle and at the bottom. This is because contaminants can settle at different levels, initial testing should be done from outside the confined space by inserting a sample probe, atmosphere tests include airflow, oxygen content, airborne concentration of flammable or potentially harmful contaminant for example hydrogen sulfide, carbon monoxide and methylene chloride never trust your own sensors to determine if the atmosphere in confined space is safe. Many toxic or flammable gases and vapors cannot be seen or smelled nor can the level of oxygen present be determined a competent spotter fully equipped with protective equipment and two fire extinguishers is suitably positioned to monitor conditions and check for any possible fires caused by the hot work in the case of a fire. 

Spotters will immediately raise an alarm, stop the hot work operation and assist with putting out the fire spotters also have the authority and responsibility to ensure that non-essential people are removed from the immediate work area and further to keep people out of the barricaded working areas workers continuously clean working areas and maintain fire hazard free conditions throughout the task execution at regular intervals the safety of the work area is reassessed and safety conditions restored when required post-hot work and confined space entry requirements on completion of the work the supervisor must conduct an inspection of the work area and systems to ensure that there is no smoldering for 30 minutes after hot work completion equipment is removed and working areas cleaned all persons are clear and accounted for all covers guards and doors are in place and secured automatic fire suppression systems are reactivated and the registers signed off permits cancelled and signed off by workers and supervisor all safety equipment returned in good working order isolation and lockout removed confined space rescue drills shall be carried out annually and records of these drills with signatures of those who took part in the drill will be kept by the immediate supervisor.