Transcript Fatality Prevention Standard in Indiana Harbor (FCA

Corporate Health and Safety
ArcelorMittal
Confined Spaces
training
March 4th , 2011
Summary
1) Introduction
2) Definitions
3) Responsibilities
3.1) Permit Issuer
3.2) Permit Receiver
3.3) Responsible Officer
3.4) Managers and Supervisors
3.5) Safety Departments
3.6) Contractors
3.7) Authorised Entrant
3.8) Standby Person
4) Confined Space Entry Process
4.1) Additional for Man – Baskets
5) Confined Space Procedures
6) Atmosphere Conditions in and around
Confined Spaces
6.1) Oxygen DEFICIENT Atmospheres
6.2) Oxygen ENRICHED Atmospheres
6.3) Flammable Atmospheres
6.3.1) Definitions
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6.4) Toxic Atmospheres
6.5) Mostly common Gases in
Confined Spaces
6.6) Lower Explosive Limit vs. Upper
Explosive Limit
7) Atmosphere testing before entering
7.1) Testing instruments
8) Preparing for Entering a Confined
Space
8.1) Ventilation
8.1.1 Ventilation forms
8.2) Isolation of Space
8.3) Standby Person
8.4) Rescue and Emergency
8.4.1) What are some emergency
response precautions?
9) Personal Protection Equipments (PPE)
9.1) Maintenance of PPE
10) Is worker training important?
11) Potential Hazards Overview
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1. Introduction
Working in confined spaces presents a variety of
hazards and increased risk of injury to those in the
immediate area.
The Occupational ArcelorMittal Health & Safety
Regulation, establishes specific requirements for
safe entry into confined spaces.
This guideline details controls to be adopted for
entry to or work in or around a confined space.
This document is based on specific legislative
requirements as contained ArcelorMittal Standard
for Confined Spaces
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1.1 REX
Build up of asphyxiate or toxic gas
Sept 08 and Jan 10
CO – Gas Fatality
• Lazaro Cardenas Jan 2010 Fatality
Victim went to take an oil sample in the oil deposit of the hydraulic
system of the Bischoff in Blast Furnace area. Apparently the
cause of death was due to a non noticed gas presence (CO) in the
area of the seal of the piston No.1. The victim decided not to use a
breathing mask with air line and went alone without gases
detector.
• Saldhana Sept 2008 Fatality
As the flange was lifted from its position using a crane, a large
quantity of CO rich gas escaped as a result of an unexpected
opening of one of the isolating valves. This caused a sudden
build-up of CO-gas in the immediate environment. The deceased
and his colleagues at that point in time were positioned on the 5
meter level, next to the flange. Due to the amount of gas escaping
in the vicinity of the 3 employees, the CO monitors used went into
the alarm mode. The deceased together with his colleagues
attempted to evacuate, but due to the intake of CO gas at the
compressor, they inhaled CO via their independent air-line supply.
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1.1 REX
Build up of asphyxiate or toxic gas
April 08 and June 09
Nitrogen – Gas First Aid / Methane – Gas Fatality
Nitrogen
• Vanderbijlpark April 2008 First aid
A colleague noticed that the victim was losing consciousness after
he had instructed him to insert the last bolt of the keeper plate for
the limiting stopper. He himself also started to feel dizzy. Another
colleague saw what was happening and grabbed the victim on his
arm and removed him from the area. He immediately suspected that
there was gas in the area even though their gas monitors had not
given an alarm. He suspected that it could be nitrogen exposure. He
had the nitrogen supply to the gearbox checked : it was noticed the
nitrogen valve was still open.
Methane
• Tenteskaya June 2009 Fatality
The concentration of methane in the face was 0.4-0.5% and 0.45%
in the return air; the conditions of the face was satisfactory. The
concentration of methane in return air increased up to 0.7%. The
operator of air and gas control informed the shift manager of this
increase. Then there was a sharp increase of methane
concentration. The stand-by auxiliary fan switched on automatically
and its shutoff took place straight away.
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1.1 REX
Explosive mixtures or zones of explosive atmospheres
October 10
Fatality
• Vinton October 2010 Fatality
On Monday October 18, 2010 at about 2:30 a.m. the victim, an equipment operator with 4 years of seniority in
this department, was helping the crew in startup preparations (it is routine to stop production at 11 pm Friday
and start up Sunday night shift for the coming week operations, on 5 day working schedule). It is believed that
he started lighting up of the tempering furnace.
At this time, the assumption is that the victim had started the lighting process and during this process, the
explosion occurred.
Before this incident, gas was not detected (by smell) by the crew nor the supervisor of the shift. Immediately
following the sound of the explosion, the work crew (operators and supervisor) initiated the emergency
procedure, which included workforce count.
The victim was found on the floor unconscious, adjacent to the furnace, with refractory material and furnace
roof metal plates around him, suffering from a severe head-face trauma.
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1.1 REX
Engulfment in confined space by collapsing material
December 10
Fatality
•Termitau December 2010 Fatality
A team consisting of 3 men was removing a hanging charge (cleaning of bunker). The victim was in a danger
zone of possible charge coal collapse at the bottom of the bunker at the height of 3m and was staying on a
metal ladder installed in the bunker (height of ladder – 12 m), he wore a harness and the too long lanyard he
used was attached (fastened) to the harness.
Two supervisors were on the upper platform of the bunker, they should ensure the safety of the victim. They
fastened the lanyard to the top step of ladder .
Since the safety lanyard attached to the harness of the victim was too long, when charge coke collapse
happened (charge fell down from the bunker walls), the coke hit the victim who fell down on the bottom of
the bunker and was covered with batch mixture (sanded-in), as a result he suffered fatal injury (asphyxia of
respiratory tract).
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1.1 REX
Atmospheres not having safe level of oxygen,
in particular due to presence of CO, CO2, Ar, N2
December 09
Fatality
• Newcastle December 2009
Multiple Fatalities
Three persons entered the vessel via the cat ladder with gas monitors on their person. On reaching a particular
level the persons collapsed onto the platform. The gas monitors were seen to give an alarm by the operator on
top of the furnace, and the persons collapsed almost simultaneously. Owing to the fact that one person’s leg was
caught in the cat ladder, the platform could not be raised to evacuate the persons. A further two persons entered
the vessel via the cat ladder in an attempt to rescue the persons on the platform; they too collapsed and fell
beneath the platform.
The cause was an oxygen deficiency due to apparent ingress of argon through the bottom stirring system due to
an inadequate isolation of bottom stirring gas
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1.1 REX
Atmospheres not having safe level of oxygen,
in particular due to presence of CO, CO2, Ar, N2
February 11
Fatality
•
Gent February 2011 Fatality
In the evening the flexible hoses of the bottom stirring were reconnected, but the Nitrogen and Argon circuits
were still under isolation, both protected with a block and bleed system.
The operator took property of the isolation to guarantee that Nitrogen and Argon remained locked out. Later he
started the work in the BOF together with his colleague to remove the scaffold. The work has been started
without wearing a multi-gas meter as up till now in the investigation, they were not found yet.
When trying to remove the first part of the work platform, The operator fell unconscious, while his colleague
was out of the BOF. The first idea was not linked to gas risk and his colleague called in an AMG maintenance
worker for help. With the elevator cage, he went down ( +/- 12 m) in the BOF, felt immediately the lack of
oxygen and fell also unconscious. Local AMG workers linked now the accident with gas, and threw a
compressed air hose in the BOF. The emergency services which had been called, came to the spot and
evacuated both victims out of the BOF. They were able to reanimate the second victim. The reanimation
attempts on the first worker however failed
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2. Definitions
Confined space is any enclosed or partially enclosed space or
spaces where movement is limited or physically restricted and that :
1. has limited or restricted means of entry or exit (sometimes needing a
mechanical system) and
2. is large enough for a person to enter to perform tasks and
3. is not designed or configured for continuous occupancy or work and
4. may have at any time an atmosphere with potentially harmful
contaminants, an unsafe level of oxygen, stored substances that may
cause engulfment or where there is a risk of death or serious injury
from hazardous substances or dangerous conditions and
5. present special hazards to workers, including risks of toxic or
asphyxiant gas accumulation, fires, falls, flooding, and entrapment
may be classified as permit-required confined spaces depending on
the nature and severity of the hazard.
It is not possible to provide a comprehensive exhaustive list of confined spaces. Some places may
become confined spaces when work is carried out, or during their construction, fabrication or
subsequent modification.
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• Confined spaces can be below or above ground.
• Confined spaces can be found in almost any workplace.
• A confined space, despite its name, is not necessarily small.
• Confined spaces include, but are not limited to:
– Storage tanks, silos or areas of storage, vats, hoppers, utility vaults, tanks, sewers,
pipes, access shafts, truck or rail tank cars, aircraft wings, process vessels, boilers,
pressure vessels, tank-like compartments that have only a manhole for entry,
ceiling and floor spaces, spaces occupied by pipes and cables (considering
galleries in particular). Ditches and trenches may also be a confined space when
access or egress is limited
– Open-topped spaces such as pits, or grease traps, or excavations more than 1.5
meters deep.
– Pipes, pumps, sewers, shafts, ducts, drains, tunnels, cellars, spaces under
equipments/installations, basements and similar structures.
– BOF (Basic Oxygen Furnace) vessel, EAF (Electric Arc Furnace) vessel etc …
since entry / exit is not easy and / or gas may be present
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•.
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Categorizing Work Space
• Space large enough to enter and
• Limited or Restricted entry or exit and
• Not designed for continuous worker
occupancy.
YES
NO
Not a confined Space
Confined Space
In addition, it contains one
or more of the following
Hazardous Atmosphere
Permit
Required
Confined
Space
YES
Or
Engulfment Hazard
Or
Configuration Hazard
Or
NO
Non
Permit
Required
Confined
Space
Any other recognized
serious hazard
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Permit-required confined space
• "Permit-required confined space (permit space)" means a confined space where one or
more of following hazards are present;
–
–
–
–
The potential to contain a hazardous atmosphere (AM ST 012)
Not have a safe level of oxygen ( e.g. following a nitrogen purge)
The potential for engulfing the entrant
A configuration that might cause an entrant to be trapped or asphyxiated by
inwardly converging walls or by a floor that slopes downward and tappers to a
smaller cross section
– Contains any other recognized serious safety or health hazards that can’t be
eliminated and the confined space can’t be maintained in a condition safe to enter.
In those cases the entry points must clearly indicate that a permit is required prior to entry.
Non Permit-required confined space
• “Non-permit confined space” means a confined space that doesn’t contain or, with
respect to atmospheric hazards, doesn’t have the potential to contain any hazard
capable of causing death or serious physical harm
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3. Responsibilities
3.1 Permit Issuer
• Ensure that hazards associated with the confined space have been:
– Identified
– Assessed
– Appropriate controls adopted.
• Inform Permit Receiver:
– The locations of the spaces and the potential hazards associated with the
respective spaces
– The requirement that only authorised, trained personnel may enter the spaces
using the procedures outlined in these guidelines.
• Ensure completion of entry permit is issued.
• Ensure that all personnel involved in the work are properly trained to perform the
required tasks.
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3.2 Permit Receiver
• Adhere to the Entry Permit requirements.
• Ensure the job is performed in a safe manner.
• Inform Entrants and Standby Persons of the locations of the spaces, the potential
hazards associated with the respective spaces, and the requirement that only
authorised, trained personnel may enter the spaces using the procedures outlined in
these guidelines.
• Be aware of the hazards that could exist and have the necessary controls in place.
• Satisfy themselves that they understand the requirements of the permit.
• Be skilled, qualified trained and competent to perform this work.
• Ensure that appropriate control measures are followed (e.g.: placement of locks and
tags according to lock-out/tag-out procedures, ventilation if necessary).
• Communicate entry permit requirements to any authorised entrant working in the
space.
• Make equipment and area safe performing above tasks.
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3.3 Responsible officer
• Ensure that contractors engaged by ArcelorMittal are aware of any occupational
health and safety hazards that may exist in the area in which they are working.
• Ensure that contractors work safely and complete the work as specified in permits and
other associated documents.
• Ensure that prior entering a confined or a permit space, a risk assessment has been
conducted.
• Ensure that before an employee enters a permit space, the internal atmosphere has
been tested with a calibrated direct-reading instrument in the following order:
– Oxygen content (oxygen-deficient or oxygen-enriched atmospheres)
– Flammable gases and vapors
– Potential toxic air contaminants
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3.4 Managers and Supervisors
• Supervisors must understand the work for which a permit has been sought and understand
isolation and Lockout / Tagout ArcelorMittal procedures,
• Ensure adequate protection is provided to the entrants by verifying adequate Lockout / Tagout
and that all hazards are securely isolated.
• Ensure that all personnel involved are aware of the hazards associated with the space.
• Ensure that a permit is granted before work starts.
• Ensure that the person(s) doing the work are appropriately qualified to do the work.
• Ensure that all checks are undertaken to ensure that the permit was used correctly.
• Ensure that rescue services informed and available as possible prior to entering.
• Ensure appropriate persons are informed when a job is completed or suspended and that the
permit is cancelled.
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3.5 Safety Departments
• Provide technical guidance on the application of these guidelines.
• Evaluate and update the permit to work guidelines at the review period or as
procedures change.
• Provide safety expertise and regulatory guidance to Permit Issuer.
3.6 Contractor
• Comply with the requirements as detailed in these guidelines.
• Ensure entry to a confined space is carried out under a work permit and in accordance
with ArcelorMittal Safety Standard Confined Space.
• Provide evidence of confined space training to permit issuer, authorised entrants,
standby persons and supervisors.
• Shall not enter a confined space without a granted ArcelorMittal confined space
permit.
• Prepare safe work procedures and/or risk assessments for confined space work prior
to entering.
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3.7 Authorised Entrant
• Assessed as competent to enter a confined space
• Understand the potential entry hazards and be aware of signs and symptoms of
hazardous environment exposure.
• Ensure that appropriate control measures are followed (e.g.: placement of locks and
tags according to lock-out/tag-out procedures, ventilation if necessary).
• Ensure that there exist defined criteria to determinate if periodic re-testing is
necessary depending on operations and conditions in and around the permit space.
• Maintain communication with the Standby Person at all times.
• Evacuate the space immediately upon an emergency, a gas detector alarm occurs or
notification by the Standby Person.
• Alert the Standby Person and exit the space immediately whenever:
– a warning sign or symptom of exposure to a dangerous situation is recognized
– a prohibited condition is identified
– an evacuation alarm is activated.
• Follow the requirements as stipulated on the confined space entry permit
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3.8 Standby Person
• Remain outside the Confined Space at all times or until relieved by another Standby Person.
Activities that may interfere with these duties are prohibited.
• Observe the work conditions in the confined space
• Monitor entrants during the job and during entry & exit to help insure their safety.
– The attendant may not abandon his post for any reason while personnel is in the space
unless relieved by another qualified attendant.
• Control if entrants properly use/worn their PPE
• Monitor continuously atmospheric conditions in the space prior to and during work (if needed).
• Control if the ventilation system is running well (if needed)
• Control access to the confined space.
• Assess hazards in and around the space, and take measures if needed.
• Keep records related to the confined space work, such as air test results, personnel entry/exit,
etc…
• Maintain continuous communication with the Authorised Entrants so as to be aware of any
problems, which may occur.
• Initiate emergency procedures, including rescue procedures, if necessary.
• Stop the job & evacuate the people if any non conformity (internal or external) is detected
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4. Confined Space Entry Process
Prior to entry of a confined space Own personnel or Contractor personnel are required
to:
1. Realise a new/own HIRA and compare it with the existent one.
2. Complete a confined space entry permit (in accordance with ArcelorMittal
Standard if needed)
3. Obtain a ArcelorMittal permit for confined space entry (if needed)
4. Verify that all personnel involved in confined space entry are aware and
understand their responsibilities
5. Verify that personnel are trained in accordance with requirements of confined
spaces
6. Provide the necessary safety equipment, supplies and monitoring equipment to
their personnel. Key items include atmospheric monitoring devices, barricades to
isolate work area, communication devices for the entrant and stand-by persons
and adequate lighting.
7. Wear all PPE’s, safety harnesses‘ and other devices requested by the approved
risk assessment.
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4.1 Permit system
– The permitting process must include the following elements:
• A Risk Analysis, including the need for a competent person to assess such risks as
oxygen or contaminants levels, temperature extremes, and concentrations of
flammable substances
• Isolation procedures for contaminants and other energy sources
• Need for ventilation, the requirement for breathing apparatus
• The sign-in and sign-out of all persons entering the confined space; internal lighting
and signalling
• Emergency lights, auxiliary lights
• Atmospheric protection conditions;
• Display of the permit
• Communication equipment
• Safety specification of equipment to be taken into the confined space
• Barricading (isolated the work area)
• Rescue plan and equipment
• Standby person
• All the work procedures.
• Modification possibilities:
– If a new hazard is recognized or introduced during the course of work, then the
permit must be modified and revalidated
The Risk Analysis may require that people working in confined spaces wear a safety
harness, connected with a cable or cord extending outside the confined space, allowing
easy evacuation in case of emergency
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5. Confined Space Procedures
The internal site procedure must refer to the Law and
the ArcelorMittal Standard ST 002 and ST 012
–
–
–
–
–
–
–
–
An identification register of all existing Confined Spaces and Restricted Areas on site
A risk assessment must be performed prior to any work occurring in the confined space.
Different confined space entry permits are required for entry into a space, depending on the
type of work being conducted such as cold or hot work.
Isolation of all potentially Hazardous Services prior to entry into the confined space
hazardous services that are normally connected to the confined space must be isolated or
otherwise controlled.
Air monitoring must be performed prior to entry into the confined space.
If work stops for a period of more than 1 hour and the confined space has not been occupied
for this period a new gas test will be required.
Prior to entry, the confined space must be cleared of all contaminants (purging)
An emergency plan should be documented and communicated to all persons working in or
around the confined space
Any person required to issue/receive permits or work in or around a confined space must be
appropriately trained and assessed as competent prior to undertaking these activities.
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6. Atmosphere Conditions in and around
Confined Spaces
The below pictures shows different ranges of Oxygen in the Air.
To work in safe conditions in the confined space the oxygen level
must be between (19,5 – 22,5) %
Oxygen deficient atmosphere starts from < 19,5 %
Oxygen enriched atmosphere starts from > 22,5 %
In both cases entry into confined spaces is prohibited
Difficult
breathing,
death in
minutes
6%
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Impaired
Faulty
judgement
judgement,
rapid, fatigue and breathing
16 %
14 %
Minimum
for Safe
Entry 19.5
%
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Maximum
for Safe
Entry 22.5
%
Oxygen
enriched,
extreme
fire hazard
> 22.5 %
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6.1 Oxygen DEFICIENT Atmospheres
19.5 %
15 - 19%
12 - 14%
10 - 12%
8 - 10%
6 - 8%
4 - 6%
Minimum acceptable oxygen level.
Decreased ability to work strenuously.
Impair coordination. Early symptoms.
Respiration increases. Poor judgment.
Respiration increases. Lips blue.
Mental failure. Fainting. Nausea
Unconsciousness. Vomiting.
8 minutes
 fatal,
6 minutes
 50% fatal
4 - 5 minutes  possible recovery.
Coma in 40 seconds  Death
Oxygen Deficiency Can Be Caused by CONSUMPTION
•
•
•
•
“Hot work” (welding)
Breathing
Chemical reactions (ex. Oxidation of chemicals or metal)
Biological action (ex. Decomposing organic matter)
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6.1 Oxygen DEFICIENT Atmospheres
Oxygen Deficiency Can Be Caused by DISPLACEMENT
Not having a safe level of oxygen, in particular due to presence of:
•
•
•
•
•
•
•
•
•
•
Argon (Ar)
Nitrogen (N2) (e.g. following nitrogen purge).
Helium (He)
Carbon monoxide (Co)
Carbon Dioxide (Co2)
Bacterial actions (fermentation process)
Formation of rust on the surface of the confined space (iron oxide/ corrosion)
Consumption of air by the amount of people working in a confined space
Cleaning agents, adhesives, or
Other chemicals
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6.2 Oxygen ENRICHED Atmospheres
• Oxygen level above 22.5%.
• Causes flammable and combustible materials to burn violently
when ignited.
– Hair, clothing, materials, etc.
– Oil soaked clothing and materials.
• Never use pure oxygen to ventilate.
• Never store or place compressed tanks in a confined space.
Liege Feb 2008 Fatality
Cellar
• The two victims went out to the cellar to carry out a
simple work. Suddenly, the atmosphere was kindled
and the fire took the two people. One died directly, the
other died at hospital. The origin of the accident was a
very high concentration of oxygen due to a leak in an
oxygen pipe that was buried outside the building.
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Leak of oxygen
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6.3 Flammable Atmospheres
• 2 Critical Factors:
– Oxygen content in the air.
– Presence of a flammable gas, or vapor
– Presence of dust (visibility of 5 inches/ 12 cm
or less)
• Proper air/gas mixture can lead to explosion
• Typical ignition Sources:
– Sparking or electric tool.
– Welding / cutting operations.
– Smoking
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6.3.1 Definitions TLV-STEL and TVL-TWA
• The threshold limit value (TLV) of a chemical substance is a level to which it is believed a
worker can be exposed day after day for a working lifetime without adverse health effects.
• The TLV for chemical substances is defined as a concentration in air, typically for inhalation or
skin exposure. Its units are in parts per million (ppm) for gases and in milligrams per cubic meter
(mg/m³) for particulates such as dust, smoke and mist.
• Threshold limit value – Short-term exposure limit (TLV-STEL) : spot exposure for a given
substance in the air of the workplace, to which the worker may be exposed for a short time
(duration of 15 minutes, that cannot be repeated more than 4 times per day)
• Threshold limit value –Time weight average (TLV-TWA) : indicates the average concentration in
air of workstations in a given pollutant that, given the current state of knowledge, does not
endanger the health of the vast majority of healthy workers exposed to them, and this for a
duration of 42 hours per week, a rate of 8 hours per day, for long periods. The pollutant in
question may be in the form of gas, vapor or dust
• The TLV-TWA must always be respected
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6.4 Toxic Atmospheres
• Stored Products Source:
– Gases released when cleaning. (e.g.: purging by Argon (Ar))
– Materials absorbed into walls of confined space.
– Decomposition of materials in the confined space.
• Source by work performed:
– Welding, cutting, brazing, soldering.
– Painting, stripping, scraping, sanding, degreasing.
– Sealing, bonding, melting.
• Areas adjacent to a confined space: venting or entering into space
Gas
Hydrogen Sulphide (H2S)
Carbon Dioxide (CO2)
Carbon Monoxide (CO)
Nitrogen Dioxide (NO2)
Nitrogen Monoxide (NO)
Sulphur Dioxide (SO2)
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(TLV-TWA) Limit (TLV-STEL) Limit 15
8 Hour work shift min work working
[ppm]
5
5
35
1
25
2
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[ppm]
20
30
50
3
50
5
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6.5 Mostly common Gases in Confined Spaces
and Gas Hazard Atmospheres
6.5.1 Carbon Monoxide (CO)
•
•
•
•
Colorless chemical asphxiant / odorless gas / flammable gas / Deadly!
Quickly collapse at high concentrations
Slightly lighter than air
Primary source:
– incomplete combustion of organic material
Carbon Monoxide
– Gasoline-fueled combustion engines
(CO)
– ….
Australia
• Signs/Symptoms:
China
– Confusion. Dizziness. Headache. Nausea.
Japan
Czech Republic
– Unconsciousness. Weakness.
Hungary
Possible human effects if you are trapped in Carbon Monoxide
atmosphere with this different high exposure levels
PPM
35
200
400
800
1 600
3 200
6 400
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Effect
Time
Permissible Exposure Level
Slight headache, discomfort
Headache and nausea
Headache, dizziness, nausea
Headache, dizziness, nausea
Headache and dizziness
Headache and dizziness
8 hours
2 - 3 hours
1 - 2 hours
45 min.
20 min.
5 - 10 min.
1 - 2 min.
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Kazakhstan
Poland
Romania
Begium
France
Germany
Netherlands
Spain
UK
Brasil
Mexico
South Africa
USA
Canada
(TLV-TWA) Limit
8 Hour work shift
[ppm]
30
20
50
30
33
20
23
20
25
50
30
29
25
35
39
50
55
25/35
25
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6.5.2 Hydrogen Sulfide (H2S)
•
•
•
•
Colorless / Very strong asphyxiant with rotten egg odor / flammable gas / Deadly!
Odor threshold: 0.02-0.2 ppm
Heavier than air
possibly no warning at high concentrations
• Primary source:
– incomplete combustion by-product of the decomposition of organic matter / 4 times
–…
• Signs/Symptoms:
– Strong odor BUT Fatigues your senses .
– Very high concentrations lead to cardio respiratory arrest because of brainstem toxicity.
– Affect nervous system
Possible human effects if you are trapped in Hydrogen Sulfide
atmosphere with this different high exposure levels
PPM
10
50 - 100
100
250 - 350
500 -600
>1000
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Effect
Permissible Exposure Level
Mild Irritation - eyes, throat
Desensitizes olfactory nerve
Unconsciousness, death
Unconsciousness, death
Unconsciousness, death
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Time
8 hours
1 hour
2 - 5 min.
4 - 8 hrs.
30 - 60 min.
minutes
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6.5.3 Methane (CH4)
• Colorless/odorless flammable gas, or scented
• Natural gas, swamp gas.
• Primary source:
– Due to gas leak or organic decay
• LEL = 5%; UEL = 15%
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6.5.4 Argon (Ar)
• Colorless / odorless, non-flammable gas and tasteless mixture, it
is the most abundant of the noble gases on Earth and the one
most used in industry
• Heavier than air.
• Primary source:
– Purging of confined spaces
– Firefighting in electrical or computer rooms
– BOF (Basic Oxygen Furnace) vessel,
– EAF (Electric Arc Furnace) vessel
• The main health hazard associated with releases
of this gas mixture is asphyxiation by displacement
of oxygen
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6.6 Lower Explosive Limit vs. Upper Explosive Limit
Definitions:
Lowest concentration (percentage) of a gas or vapour in air capable of producing a flash of fire
in presence of an ignition source ( arc, flame, heat).
Concentrations lower than Lower Explosive Limit (LEL) [ Lower Flammable Limit (LFL)]
are 'too lean' to burn.
Concentrations lower than Upper Explosive Limit (UEL) [ Upper Flammable Limit (UFL)]
are 'too rich' to burn.
Important to point out where 10% LEL is in relation to LEL.
Concentration in Air
Too rich
Flammable
Region
LEL
Too lean
10% LEL
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Flash Point
Temperature
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Why is 10% used?
• The combustible gas detection instrument measures
% LEL, not Actual % gas in air. Depending on
calibration gas used, some gases will give a much
lower LEL reading than the actual LEL concentration.
• Their is a very small percentage difference at 10%.
For this reason, 10% LEL should be used as the max
LEL concentration for worker entry.
Methane example
Air
100%
Too Lean
Methane
0%
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It’s always a good idea to keep the
fire
and/or
explosion
triangle in mind.
Air
0%
Too Rich
5.3%
LFL
Boom!
15.0%
UFL
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Methane
100%
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6.6 Lower Explosive Limit vs. Upper Explosive Limit
• Before a person enters a confined space, it shall be ensured;
– the concentration of flammable contaminant in the atmosphere is below 5 % of its LEL
– Entry shall not occur to a confined space when flammable contaminants are greater than or
equal to 5% LEL
– Where a concentration of flammable contaminant is found to be more than 5% and less than
10% of its LEL, all persons must leave the confined space unless a continuous monitoring,
suitably calibrated flammable contaminant detector is used in the confined space at all times
while persons are present in it.
– Where a concentration of flammable contaminant in the atmosphere of a confined space is
found to be 10% of its LEL or more, all persons must leave the confined space.
Gas
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"Lower Explosive
or Flammable
Limit" (LEL/LFL)
"Upper Explosive
or Flammable
Limit" (UEL/UFL)
(%)
(%)
Hydrogen - H
Methane - CH4
4
5
75
15
Ammonia - NH3
15
28
Acetylene (ethyne) - C2H2
2.5
81
Carbon monoxide - CO
12
75
Ethylene (Ethene) - C2H4
2.75
28.6
Ethane - C2H6
3
12.4
Cyclopropane
2.4
10.4
Propane - C3H8
2.1
10.1
Benzene - C6H6
1.35
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7. Atmosphere testing before entering
• Air monitoring is required to be performed prior to entry into the confined
space to ensure that the atmosphere is safe prior to entry.
• If work stops for a period of more than 1 hour and the confined space has
not been occupied for this period a new gas test will be required.
• After ventilation period (if ventilation is necessary);
• Initial testing should be carried out by a “Competent person” who will issue a
certificate stating whether the space is ‘safe for man’ and/or work, and if any
special conditions are to be observed.
• In no case should the operator / worker is considered to be a “Competent
Person” – even if he is equipped with his own personal testing equipment.
• Ventilation should be stopped about 10 minutes before tests are made and
not restarted until the tests are completed.
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7. Atmosphere testing before entering
• The testing should be carried out in the following sequence
– Oxygen-deficient or -enriched atmospheres
– Flammable atmospheres
– Toxic atmospheres when considered necessary
• To evaluate the measurements taken, the following limit values should be used.
• Continuously monitoring is required for the whole work period
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Always test the air at VARIOUS levels to be
sure that the entire workspace is safe
Top of vessel
• Good Air
Good air near the
opening does
NOT mean there
is good air at the
bottom !
Middle of vessel
• Poor Air
Bottom of vessel
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This constellation
is NOT all the time
given (see example
next page)
• Deadly Air
40
Specific
Gravity1)
Gas
- SG - ( kg/m3)
• See some examples of Specific Gravity
( kg/m3) of Gases.
These gases are
LIGHTER than Air
These gases are
SAME than Air
These gases are
HEAVIER than Air
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Hydrogen
0.0696
Helium - He
0.138
Coke Oven Gas
0.44
Methane - CH4
0.5537
Ammonia - NH3
0.59
Natural Gas (typical)
0.60 - 0.70
Acetylene (ethyne) - C2H2
0.90
Carbon monoxide - CO
0.9667
Nitrogen - N2 (pure)
0.9669
Ethylene (Ethene) - C2H4
0.9683
Nitrogen - N2 (atmospheric)
0.9723
Air
1
Blast Furnace gas
1.02
Ethane - C2H6
1.0378
Oxygen - O2
1.1044
Hydrogen sulfide - H2S
1.1763
Hydrogen chloride - HCl
Fluorine
Argon - Ar
1.268
1.31
1.38
Carbon dioxide - CO2
1.5189
Propane - C3H8
1.5219
Nitrous oxide - N2O
1.530
Ozone
1.660
Sulfur Dioxide - SO2
2.264
Benzene - C6H6
2.6961
R-11 --> 134a
4.174 --> 5.9
41
7.1. Testing instruments
The examples shown in the next slides are just 2 of many other existing atmosphere testing
devices on the market.
Fill free to make your own choice !
Examples of single gas detector(s):
Warns Against Hazardous Gas Concentrations
• The device reliably warns against hazardous concentrations of the following: carbon
monoxide (CO), hydrogen sulphide (H2S), oxygen (O2), carbon dioxide (CO2), sulphur
dioxide (SO2), chlorine (Cl2), hydrogen cyanide (HCN), ammonia (NH3), nitrogen dioxide
(NO2), nitrogen monoxide (NO), phosphine (PH3) and organic vapours.
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Examples of single gas detector(s):
Warns Against Hazardous Gas Concentrations
• The device reliably warns against hazardous concentrations of the following:
Carbon Monoxide (CO), Oxygen (O2) .
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Examples of single gas detector(s):
Warns Against Hazardous Gas Concentrations
• These Hands Free Single Gas Monitor can detect Carbon Monoxide (CO),
Hydrogen Sulphide (H2S), or Oxygen (O2) gases.
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Examples of multi gas detector:
Warns Against Hazardous Gas Concentrations
• The device reliably warns against hazardous
concentrations of the following by changing the sensors:
• Ammonia (NH3), Arsine (ASH3), Carbon Monoxide (CO),
Chlorine (Cl2), Hydrogen Cyanide (HCN), Hydrogen
Sulphide (H2S), Phosphine (PH3), and Sulphur Dioxide
(SO2).
Special Accessories for this detector
• Its unique extender cable allows the sensor to be
attached to the end of a 10 foot (+/- 3 m) cable for
remote monitoring and quick response.
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Examples of 4 gas detectors:
Warns Against Hazardous Gas Concentrations
• The 1 to 4 gas detector reliably detects combustible
gases and vapours as well as O2, CO and H2S.
•
• The very compact design - no larger than a mobile
phone - and low weight make the device the ideal
companion in your daily work.
Special Accessories for this detector
• An external pump, which can be operated with a
hose of a length of up to 20 m, is the perfect solution
for remote measurement applications as of tanks,
shafts, etc.
• Attention : By using external pumps to extract the
gas from tanks it takes a several time to measure the
correct gases.
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Examples of 4 gas detectors:
Four Gas Confined Space Monitor
• The 1 to 4 gas detector reliably detects simultaneous
detection of 4 gases, LEL, O2, H2S & CO
• The very compact design - no larger than a mobile
phone - and low weight make the device the ideal
companion in your daily work.
Special Accessories for this detector
• An external pump, which can be
operated with a hose of a length of up
to 20 m, is the perfect solution for
remote measurement applications as of
tanks, shafts, etc.
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8. Preparing for Entering a Confined Space
Example of controlling a Confined Space (1)
Before entering in Confined Space, it is mandatory, to control this space with a gas
detector.
If the cave is too deep, wide,…, a special devices, as an adapted stick, rod, is to
use to control the atmosphere .
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Example of controlling a Confined Space (2)
How using the adapted stick:
Use a adapted stick, fixe the 4 gas detector on it, hold it at mini. 20 seconds into
the confined space, take it of, read the result and repeat the test in the 4 directions
(up, down, left or right and depth)
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8. Preparing for Entering a Confined Space
8.1 Ventilation
• Before a person enters a confined space, it shall be ensured;
– the atmospheric contaminants in the confined space are reduced to below the
relevant exposure standards
• If concentrations of materials are found to be at harmful levels, the confined space
must be ventilated to remove them before entry.
• Ventilation should be continuous where possible because in many confined spaces
the hazardous atmosphere will form again when the flow of air is stopped. All
openings are to be opened for ventilation including emergency exit.
• De-ballasting a tank does not guarantee a safe atmosphere. Testing of the
atmosphere is still required.
• The inert gas fans should not be used to provide fresh air ventilation because
contaminants from the inert gas lines could be introduced into the tanks.
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8.1.1 Ventilation forms
• Use mechanical ventilation
– Fans
– Air horns
• Make sure air supply is not contaminated
– Ventilation air supply must be from fresh air
uncontaminated with flammables, toxins, etc.
– Localized exhaust ventilation is better suited to capture
fumes (welding), dust, and chemical contaminants
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Ventilation must be
continuous when there is
an existing or potential
atmospheric hazard.
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Possible Blowers & Fans problems:
• Blowers & fans provide
mechanical dilution ventilation.
Be sure the blower is
appropriately sized, explosionproof, and its intake is placed far
enough away from any source of
contamination –
like an exhaust pipe on a vehicle!
Effective ?
Effective ?
A space under positive pressure will eventually expel the contaminant through an opening,
but the time it takes is the real question.
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Possible Respiratory Protection problems
• Respirators must be worn in oxygen deficient atmospheres or when
toxins are capable of causing death, incapacitation, impairment of
ability to self-rescue, injury, or acute illness due to their health effects.
• A supplied air respirator is required for oxygen deficiency or toxic
chemical levels that are Immediately Dangerous to Life or Health
(IDLH). An air-purifying respirator (respirators that filter contaminated
air) cannot be used in these atmospheres.
• Employees must have complete training on the proper use of
respirators.
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8.2 Isolation of Confined Space
The supervisor should evaluate the need and the way how for isolation of the
confined space from service before entering the space.
A way to isolate the Space from all Hazards
• Close Valves
In order of priority :
– Physically remove the connection to the space
– Blind flange (assure it can withstand the pressure and is in good state)
– Double block & bleed as a last resort if the other two are not possible and only upon
approval of hierarchy
• Cut off any connection which could enable gas penetration.
To close valves or other armatures is not safe enough, disconnect the supplies.
• Disconnection is always required, in case an explosive atmosphere could not be excluded.
right
wrong
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8.2 Isolation of the possible energies in a Confined Space
• Empty the Confined Space
– Depressurize, vent & drain,…
• Lockout / Tagout Equipment
– Electrical sources
– Rotating/reciprocating parts
– Hazardous materials
–…
• Clean residue from the space ( e.g.: Argon purging)
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8.2 Isolation of the possible energies in a Confined Space
• Gaseous fire suppression is a term to describe the use of inert gases
and chemical agents to extinguish a fire. Also called Clean Agent Fire
Suppression .
• Lockout / Tagout must be realised in case of working in a server or
electrical room extinguished by an inert gas ( e.g.: Argon , CO2,..)
– Numerous incidents have occurred where individuals in these Confined
Spaces have been killed by carbon dioxide or Argon agent release.
– To prevent such occurrences, additional life safety systems are typically
installed with a warning alarm that precedes the agent release. The
warning, usually an audible and visible alert, advises the immediate
evacuation of the enclosed space.
– Accidents have also occurred during maintenance of these systems, so
proper safety precautions must be taken beforehand
Remember, purging a space with an inert gas
expels a flammable but leaves no oxygen.
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8.3 Standby Person
• A standby person should be assigned to remain on the outside of the confined space
and be in constant contact (visual or two-way voice communication e.g. walkie-talkie)
with the survey team inside. Routines for communication intervals with the survey
team should be established.
• The standby person:
– should not have any other duties than to serve as standby and know who should
be notified in case of emergency;
– should never leave his post even after help has arrived and is a key
communication link to others onboard;
– should be able to communicate sufficiently in a relevant common language.
• Communication between watch personnel (Bridge, Cargo Control Room or Engine
Control Room) and standby person should be established
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8.4 Rescue and Emergency
• Rescuers must be trained in and follow established emergency
procedures and use appropriate equipment and techniques
(such as lifelines, respiratory protection, standby persons).
• Emergency and evacuation procedures should be agreed and
understood by all parties involved in a potential rescue operation.
• Steps for safe rescue should be included in all confined space
entry procedures. Rescue should be well planned and evidence
should be made available that indicates drills have been
frequently conducted on emergency procedures
Note:
• Unplanned rescue, such as when someone instinctively rushes in to help a
downed co-worker, can easily result in a double fatality or even multiple
fatalities if there is more than one would-be rescuer.
• Over 50% of the workers in confined spaces die while attempting to rescue
other workers.
• An unplanned rescue could be the last!
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8.4.1 What are some emergency response precautions?
• If a situation arises where there is a hazardous condition and the worker
does not leave or is unable to leave the confined space, rescue
procedures should be begin immediately.
• The Safety Watch is qualified in confined spaces rescue procedures and
will be available immediately outside the confined space to provide
emergency assistance if needed. The Safety Watch should be familiar
with the structural design of the confined space. The Safety Watch is in
constant communication with the worker inside the confined space and
will:
– Have an alarm for calling for help.
– Have all required rescue equipment (for example, safety harnesses,
lifting equipment, a lifeline) immediately available and be trained in
its use.
– Hold a basic first aid certificate.
– Can do Cardiopulmonary Resuscitation (CPR).
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8.4.1 What are some emergency response precautions?
• The detailed plan for emergency response to an injury or other
emergency within the confined space should be described in
detail in the Confined Space Hazard Assessment and Control
Program.
• Rescue the victims from outside of the confined space, if
possible. No other worker should enter a confined space to
attempt a rescue unless that worker is fully trained in the rescue
procedures and is wearing the appropriate personal protective
equipment. More than 60% of deaths in confined spaces are
would-be rescuers, who are not fully trained and adequately
equipped.
• Another worker qualified in confined spaces rescue procedures
must be present outside the confined space before the first
rescuer enters the confined space. Do not use the same air as
the confined space workers you are rescuing. Wear SCBA (self
contained breathing apparatus) or supplied air respirator with an
escape bottle.
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9. Personal Protection Equipment (PPE)
• PPE is traditionally regarded as the last line of protection with the emphasis being placed on
avoidance and appropriate managerial control methods. However, the potentially hazardous
nature and isolated position of those entering a confined space means that, for the surveyor,
PPE may be the first line of protection.
• Each confined space will present different hazards and degrees of risk to health and safety,
the final provision of PPE should therefore be based on an assessment of risk.
• As a general rule the following guidance is offered:
–
–
–
–
–
–
–
–
–
Basic surveyor PPE should include:
Body protection (hard wearing overalls with suitable pockets for notebook, etc);
Foot protection (steel toecaps (200 joules), steel midsoles, good grip, oil resistant);
Head protection (hard hat with chinstraps);
Hand protection (hard wearing gloves);
Eye protection (protective glasses, goggles);
Ear protection (ear defenders or ear plugs – worn subject to communication system);
Gas meter - multi-gas meter for measuring of HC, H2S, CO, O2 is recommended;
Lighting (hand held with lanyard and appropriate beam width).
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9.1 Maintenance of PPE
• Clean Respirators by disassembling / washing in
warm water and mild detergent.
• Store mask and cartridges in ziplock bags.
• Use a locker to store respirators and cartridges.
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10. Is worker training important?
• Yes, appropriate training is extremely important to working safely in confined
spaces. Hands-on training should be an essential part of the confined space training.
• Every worker that enters a confined space must be fully trained on the following:
– Recognition and identification of potential hazards associated with the confined
spaces that will be entered.
– Evaluation and control procedures for the identified or potential hazards.
– All equipment such as ventilation equipment (blowers), harnesses and air
quality monitors (e.g., Oxygen/combustible meters) that will be used while in the
confined space.
– All personal protective equipment (e.g., respirators) that the worker will be using
while in the confined space.
– All procedures for entering the confined space as outlined in the employer's
Confined Space Hazard Assessment Program.
– Procedures to follow in the event of a situation developing that could present
additional risk to the worker or an emergency.
– The specific work to be done while in the confined space.
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10. Is worker training important?
• Workers with emergency rescue responsibilities will need additional specialized
training.
• All confined space training should include some hands-on training with the safety
equipment including the personal protective equipment and safety harnesses.
• Rescue procedures should be practiced frequently so there is a high level of
proficiency.
• Employers should keep records of all confined spaces training including refresher
courses.
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11. Potential Hazards Overview
Oxygen Hazards
Too much or too little
Engulfment Hazards
 Loose, granular materials stored in bins and hoppers - grain,
sand, coal, etc.
 Crusting and bridging below a worker.
 Flooding of confined space.
 Water or sewage flow.
 Shifting liquid or solid substance that traps employee
Temperature Extremes
 Extremely hot or cold temperatures.
 Steam cleaning of confined spaces.
 Humidity factors.
 Extremely cold liquids.
 Work processes inside the confined space can increase temperature extremes.
 Personal protective equipment.
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11. Potential Hazards Overview
Toxic Hazards
 Gases, vapors or fumes (examples: hydrogen sulfide, sulfur
dioxide, carbon monoxide)
Flammable or Explosive Hazards
 Vapors or dusts in concentrations large enough to ignite
Configuration
 Walls or floor which slope downward or taper in can trap an
employee
Physical Hazards
 Contact with mechanical or electrical equipment, steam or other
sources of heat, moving parts, energy.
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11. Potential Hazards Overview
Special Hazards
 Noise
– Amplified due to acoustics within the space.
– Damaged hearing, affect communication.
 Slick / Wet Surfaces
– Slips and falls.
– Increased chance of electric shock.
 Falling Objects
– Topside openings expose workers inside confined space to falling objects.
 Crushing
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11. Potential Hazards Overview
Example of possible hazards while
working in a confined space:
1. Lack of organizational safety
• Insufficient rescue measures
• missing stand by person
• Non existing work permit system
2. Lack of isolation
3. Oxygen deficiency / Oxygen excess
4. Limited entry / exit
5. Danger due to electrical powered tools
6. Electricity
7. Radiation
8. Hot or cold surfaces / mediums
9. Hazard chemical substances
10. Bad air out and NO fresh air in
Additionally to be considered:
•
•
•
•
•
Increased physically work loads
Chemical reactions
Fire / explosions
Noise
Fall
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Other Hazards
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Other Hazards
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So, WHEN IN DOUBT, STAY OUT
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Confined Space Quiz
1) A confined space means a space that:
A) Is large enough that an employee can enter and
perform work
B) Has limited or restricted means for entry or exit
C) Both A&B
D) None of the above
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Confined Space Quiz
2) Examples of confined spaces are:
A) Storage tanks, pits, silos, and vats
B) Tunnels, sewers, shafts, and exhaust ducts
C) Offices, carpools, and shopping stores
D) A&B
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Confined Space Quiz
3) True or False:
The employee must assess the workplace to
determine if hazards are present that necessitate the
use of PPE.
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Confined Space Quiz
4) Which are examples of permit space hazards?
A) Hazardous atmosphere, engulfment,
electrocution, and heat stress
B) Storage tanks, pits, silos, and vats
C) Tunnels, sewers, shafts, and exhaust ducts
D) None of the above
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Confined Space Quiz
5) What are some ways of reducing risks of hazards?
A) Post signs and use of barriers
B) Develop and use a written program
C) Conduct monitoring and ventilate, eliminate, or
control the hazards of the confined space
D) All of the Above
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Confined Space Quiz
6) Which of the following are required on a confined space
permit?
A) Permit space, purpose, date, and authorized
entrants
B) Hazards of space, control methods, acceptable
entry, and results of entry
C) Rescue and emergency services,
communication procedures, and equipment
D) All of the above
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Confined Space Quiz
7) True or False:
In the preparation of a permit space, you must notify
all affected departments, post signs and barriers to
protect entrants, and empty the confined space of
any hazardous materials.
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Confined Space Quiz
8) In the preparation of permit space, you must:
A) Blind or disconnect and cap all input lines
B) Verify breathing safety by air testing and add
emergency control telephone numbers
C) All the above
D) None of the above
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Confined Space Quiz
9) True or False:
During atmospheric testing, you must evaluate heat
stress potential and control any hazards before entry
but need not evacuate the space if the air becomes
hazardous.
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Confined Space Quiz
10) During atmospheric testing, you must:
A) Continuously test and monitor air in all areas
before entry
B) Make sure that the oxygen content is between
19.5 and 25.5 percent
C) List any toxic materials that could be present
and their permissible exposures
D) A&C
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Confined Space Quiz
11) Regarding safety procedures entering a confined
space, which of the following applies:
A) Authorized entrants can enter a permit space
only after tested and found safe
B) Each assigned entrant has to know what
equipment to use and how to use it
C) Do the task as quickly and efficiently as possible
D) All the above
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Confined Space Quiz
12) Duties of the entry supervisor include:
A) Verification of the permit and checks the condition
of the confined space
B) Sees that unauthorized people are removed
C) Cancels the permit when work is done
D) All the above
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Confined Space Quiz
13) Duties of the Stand-by person include:
A) Maintaining an accurate account of who’s
in the space, monitors activities of the space, and
stays in touch with the entrants
B) Keeps unauthorized persons away from an occupied
permit space
C) Orders the evacuation from the permit space and
summoning rescue when needed
D) All the above
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Confined Space Quiz
14) Duties of the entrant include:
A) Knowing the hazards of the space and signs of
exposure
B) Follows their personal protective equipment
training and keeps in contact with the attendant
C) All of the above
D) None of the above
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Confined Space Quiz
15) True or False:
Only workers trained in rescue can enter the space
for the purpose of rescue whether an attendant is
present or not.
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