Management of Workplace Safety, Health and
Environment
CN3135
Soh Guat Hiong
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Learning Outcomes
1. Describe the elements of SS506: Part 3: 2013 for Chemical Industry
2. Meet legal requirements of SHE management
3. Application of permit to work system
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SHE Management System
• A systematic process for managing SHE, providing for goal setting, planning, performance measurements, and clear management commitments and direction
• Helps create a safer work environment, provide a measureable system to verify SHE performance, improve business opportunities, and enhance an organisation’s reputation and image
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SHE Management Systems
A commitment by the organisation to:
• Provide a safe and health workplace for employees and contractors
• Identify workplace hazards, conduct risk assessment and control of all risks
• Managers, supervisors and employees be actively involved to prevent incidents and ill-health at the workplace
• Provide information and training for employees at all levels so they can work safely
• Audit and review the SHE management system
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Workplaces to Implement WSHMS
2nd Schedule, WSH (Safety and Health Management System and Auditing) Regulations 2009
• Worksite
• Shipyard
• Manufacturing of metal products, machinery or equipment with >100 workers
• Manufacturing or processing of petroleum, petroleum products, petrochemicals or petrochemical products
• Bulk storage of toxic or flammable liquid >5000m3
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Workplaces to Implement WSHMS under WSHA
• Manufacture of fluorine, chlorine, hydrogen fluoride, carbon monoxide and synthetic polymers
• Manufacturing of pharmaceutical products or intermediaries
• Manufacturing of semi-conductor wafers
• Audit to be conducted once every 2 years
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Workplace Safety and Health (Registration of Factories) Regulations
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Examples of SHE MS
• SS506: Part 1: 2009 Occupational Safety and Health Management Systems – Requirements
• SS506: Part 1: 2009 Occupational Safety and Health Management Systems – Guidelines for Implementation
• SS506: Part 3 : 2013 Requirements for Chemical Industry
• OHSAS 18001 : 2007 Occupational Safety and Health Management System
• ISO14001: 2004 Environmental Management Systems (revision due in 2015)
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Plan-Do-Check-Act Cycle
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Establish
objectives
and
Processes
Implement
Processes
Monitor and
measure
processes
against policy,
objectives &
legal /other
requirements
Take Actions to
Continually Improve
OSH Performance
Commitment
to OSH
a) Occupational Safety and Health Policy
• Top management endorsement
• Appropriate to nature and scale of OSH risks
• Comply with legal and other requirements
• Communicated to all employees and other stakeholders under control of organisation
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Key Requirements of SS506: Part 3 : 2013
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• Highest Standards of Performance, Business Excellence
• We will adhere to the highest standards for the safe operation of facilities and the protection of our environment, our employees, our customers and the people of the communities in which we do business. We will manage security as we do safety.
• We will strengthen our businesses by making safety, health and environmental issues an integral part of all business activities and by continuously striving to align our businesses with public expectations.
DuPont Position Statement on Safety, Health, and Environment Commitment
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• Committed to Zero Injuries, Illnesses, and Incidents
• We believe that all injuries and occupational illnesses, as well as safety and environmental incidents, are preventable, and are committed to a goal of zero for all of them. We will promote off-the-job safety for our employees.
• We will assess the environmental impact of each facility we propose to construct or acquire and will design, build, operate and maintain all our facilities and transportation equipment so they are safe, secure and acceptable to local communities and protect the environment.
• We will be prepared for emergencies and will provide leadership to assist our local communities to improve their emergency preparedness
DuPont Position Statement on Safety, Health, and Environment Commitment
Petrochemical Corporation of Singapore
• Process Safety Policy• Process safety leadership from top management level,
discussing process safety in board meetings, such as reviewing process safety indicators and performance.
• Demonstrating visibility and visible commitment of top management, through site visits and open dialogues.
• Providing a positive, trusting and open culture where PCS employees and workers are encouraged to speak out without fear or reprisal and their views on safety.
• Enhancing engineered and administrative safeguards that act to achieve or maintain a safe state of process.
• Process safety improvement plan identifying priorities for ensuring system and safeguards retain their integrity, with continual improvement.
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Petrochemical Corporation of Singapore
• Process Safety Policy
• Implementing an integrated set of leading and lagging performance indicators, which are periodically updated.
• Comprehensive maintenance program and timely rectification of faults with adequate repairs.
• Suitable training and transfer of knowledge and learning of good practices.
• Reviewing industry incidents and recommendations across major hazard sectors for learning lessons and improvement.
• Recognizing changes and ensuring that they are appropriately documented, reviewed, approved and communicated.
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b) Planning
⁻ Hazard identification, risk assessment and risk control
⁻ Legal and other requirements
⁻ Setting objectives and programmes
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Key Requirements of SS506: Part 3 : 2013
• Hazard Identification, Risk Assessment and Control
• Proactively identify all hazard sources, situations or acts that has potential to cause harm
• Routine and non-routine activities (including emergencies)
• Human behaviour, capabilities and other human factors
• Infrastructure, equipment and materials used
• New, including changes made
• Control measures and mitigation methods for worst case scenario
• Applicable legal requirements
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Key Requirements of SS506: Part 3 : 2013
• Hazard Identification, Risk Assessment and Control
• Process Safety Information required
Hazards of chemicals – Toxicity, PELs, physical/chemical properties. Get from Safety Data Sheet
Technology of process – Process flow diagram, inventory, operational limits, WSH consequences of deviation
Equipment, hardware and facility – Safety system, interlocks, detection, suppression systems, materials of construction, P&IDs, relief system, ventilation system design
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Key Requirements of SS506: Part 3 : 2013
Risk Assessment• Hazard Identification:
⁻ Physical (e.g. fire, noise, ergonomics, heat, radiation)
⁻ Mechanical (e.g. moving parts, rotating parts)
⁻ Electrical (e.g. voltage, current, static charge, magnetic fields)
⁻ Chemical (e.g., flammables, toxics, corrosives, reactive materials)
⁻ Biological (e.g., blood-borne pathogens, virus)
⁻ Psychosocial (e.g., stress, fatigue)
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Risk Evaluation
Likelihood
Severity
Rare -
1
Remote -
2
Occasional -
3
Frequent -
4
Almost
Certain - 5
Catastrophic - 5 5 10 15 20 25
Major - 4 4 8 12 16 20
Moderate - 3 3 6 9 12 15
Minor -2 2 4 6 8 10
Negligible - 1 1 2 3 4 5
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Source: Code of Practice on Risk Management, Workplace Safety and Health Council
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Risk level Risk
Acceptability
Recommended Actions
Low Acceptable • No additional risk control
measures
• Frequent review and
monitoring of hazards
Medium Tolerable • Ensure risk level is reduced
to as low as reasonably
practicable
• Interim risk control
measures
Risk Evaluation
Source: Code of Practice on Risk Management, Workplace Safety and Health Council
Risk Evaluation
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Risk
level
Risk
Acceptability
Recommended Actions
High Not Acceptable • High Risk level must be
reduced to at least Medium
Risk before work starts
• No interim risk control
measures
• If practicable, hazard should be
eliminated before work starts
• Management review required
before work starts
Source: Code of Practice on Risk Management, Workplace Safety and Health Council
Tools for hazard identification and risk evaluation
What-if Checklist
Job Safety Analysis
FMEA
Fault Tree Analysis
HAZOP
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Key Requirements of SS506: Part 3 : 2013
Risk Control • Elimination – eliminate the hazard eg. use
mechanical lifter instead of manual lifting
• Substitution – substitute with a less hazardous equipment or material eg. use bore piling instead of hammer piling for a less noisy operation
• Engineering control – use physical means to control the hazard eg. local exhaust ventilation to remove chemical hazard at source, install enclosure over machine to reduce exposure to loud noise
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Key Requirements of SS506: Part 3 : 2013
Risk Control• Administrative control – implement safe work
procedures, permit-to-work system, job rotation, install warning signages
• Personal protective equipment – use as last resort eg. safety helmet, safety glasses, respirators, protective clothing and gloves, safety boots.
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Key Requirements of SS506: Part 3 : 2013
• Ongoing review to:• Assess effectiveness of control measures
• Identify any new hazards which may arise from changes in operation
• Respond to feedback from employees
• Findings from any incident investigation and emergency situation
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Key Requirements of SS506: Part 3 : 2013
• Legal and Other Requirements
• Applicable legal and other requirements
• WSH requirements from clients or industry
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Key Requirements of SS506: Part 3 : 2013
Meeting Legal Requirements
• Workplace Safety and Health Act
• Came into effect 1st March 2006
• Covers ALL workplaces
• Managing WSH proactively. Requires stakeholders to take reasonably practicable measures to ensure S&H of workers and other people affected by work being carried out
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Meeting Legal Requirements
• Workplace Safety and Health Act
• 3 Guiding Principles
Reduce risks at source - eliminate or minimise risks created by stakeholders
Instil greater ownership of S & H outcomes by industry
Higher penalties for poor safety management
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Meeting Legal Requirements
• Workplace Safety and Health Act
• Specify liabilities for a range of persons at the workplace
• Focus more on WSH goals and systems
• Greater penalties for compromising safety and health
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Workplace Safety and Health Act
• Examples: Convictions in 2015
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Subsidiary Legislation
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• Objectives and Programmes
• Set OSH objectives to meet commitment found in OSH policy
• Achieve objectives by implementing OSH programmes
• Programmes must have action plan, persons responsible, resources required, tasks to be performed and target completion dates
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Key Requirements of SS506: Part 3: 2013
• Examples of objectives are:
• Reduce noise level in the process plants to below 85dBA
• Achieve 100% attendance in WSH training
• Organise 5 WSH programmes to increase workers awareness to workplace safety and health
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Key Requirements of SS506: Part 3: 2013
Key Requirements of SS506: Part 3 : 2013
c) Implementation and Operation⁻ Resources, roles, responsibility & accountability
⁻ Competence, training and awareness
⁻ Communication, participation and consultation
⁻ Operational control
⁻ Occupational health
⁻ Emergency preparedness and response
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• Resources, Roles, Responsibility, Accountability and Authority Top management takes ultimate responsibility for
OSH and OSH management
Visible leadership
Performance based approach to achieve objective
All stakeholders take ownership of OSH outcomes
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Key Requirements of SS506: Part 3: 2013
• In-house OSH Rules and Regulations
Operating procedures and safe work practices
Incident and hazard reporting
OSH training requirement
Use of personal protective equipment
Housekeeping and cleanliness
Fire prevention
Rules communicated, readily available to employees and contractors
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Key Requirements of SS506: Part 3: 2013
• Competence, Training and Awareness
• Training needs identified for each level of employees and contractors
• Competence – education, training, relevant experience
• OSH policy, safe work procedures and practices, OSH hazards, roles and responsibilities & consequences of departure from specified operating procedures
• Effectiveness of training
• Promotional OSH programs – Improvement teams, tool box meetings, talks
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Key Requirements of SS506: Part 3: 2013
• Communication
• OSH hazards and its OSH management system should also be communicated to:
• Employees
• Contractors and suppliers
• Visitors
• Other external interested parties
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Key Requirements of SS506: Part 3: 2013
• Participation and Consultation
• Hazard identification, risk assessments and controls
• Incident investigation
• Development of OSH policies and procedures
• Changes that can affect OSH impact
• Include contractors
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Key Requirements of SS506: Part 3: 2013
• Operational Control
• Used to manage OSH risks to an acceptable level and comply with applicable legal and other requirements
• To consider:
Routine operations, including maintenance
Non-routine operations – start-up, shutdown, foreseeable emergency operations (eg. chemical spills)
Managing hazardous substances
Managing process safety requirements
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Key Requirements of SS506: Part 3: 2013
• Operational Control
• Include consequences of deviation, steps to correct or avoid deviation and safety systems and their function
• Special precautions
• Special or unique hazards – eg dust explosion, cryogenic liquids
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Key Requirements of SS506: Part 3: 2013
• Pre-start up safety for new facilities and modified facilities
• Safe work procedures and practice – include permits-to-work
• Mechanical integrity and reliability - check process equipment to ensure that they are designed and installed correctly
• Control of hazardous substances
• Occupational health – hearing, respiratory protection, ergonomics
• Emergency preparedness and response (eg. chemical spills)
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Key Requirements of SS506: Part 3: 2013
• Management of Change
• Means and methods to detect changes
• Design basis for change
• Analysis of possible OSH hazards – apply process hazard analysis
• Authorisation requirements
• Verification of change
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Key Requirements of SS506: Part 3: 2013
d) Checking
• Systematic way to measure and monitor the OSH performance on a regular basis
• Performance measurement and monitoring
• Calibration of instruments
• Evaluation of compliance
• OSH inspection
• Incident investigation, non-conformity, corrective action and preventive action
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Process Safety Indicators
• Leading Indicators - monitor proactively the
effectiveness of risk control systems and provide
feedback on safety performance before an incident or
accident happens
• Lagging Indicators – when desired safety outcome
has failed. Monitor reactively the effectiveness of risk
control systems, identify gaps and weaknesses in
these systems, and report on incidents or accidents
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• Process Safety Indicators Examples
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Key Requirements of SS506: Part 3: 2013
Swiss Cheese Model
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Conducting Root Cause Analysis
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Incident Investigation
• Root Cause Analysis Tools
Cause and Effect Analysis
5 WHYs
FMEA
Fault Tree
HAZOP
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Cause & Effect Analysis
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CHEMICAL BURN DURING BLENDING OPERATION
Source: Case Studies: Chemical Industry, WSH Council
Incident Investigation
• Root CausesDesign problem
Control problem
Problems in operating procedure
Lack of maintenance
Management problems – resources, bad decisions
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Process Safety Hierarchy
• Inherent – Completely eliminate or significantly reduce hazards
• Passive – Safety feature added does not require action by any device or person eg. secondary containment, welded fittings vs flanges
• Active – Add safety shutdown systems eg. safety interlocks
• Procedural – Standard operating procedures, emergency response procedures, rules, training
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Process Safety Strategies
Designs for Process Safety
• Inherently safer designs – permanently eliminates and reduces hazards
• Modification in one area may increase or decrease risk in another area
Moderate: Use milder conditions
Substitute: Replace with less hazardous chemicals
Minimise: Use smaller quantity
Simplify: Easy to use designs
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Eliminate Working at Height and Exposure
to Hazardous Chemicals
Source: Case Studies: Chemical Industry, WSH Council
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Eliminate Working at Height and Exposure
to Hazardous Chemicals
Source: Case Studies: Chemical Industry, WSH Council
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Source: Case Studies: Chemical Industry, WSH Council
CHEMICAL SPLASH AT PROCESS PLANT
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In-line sampling of
chemicals. Prevent
air entering system –
minimise spillage
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Eliminate Exposure to Hazardous Chemicals
Source: Case Studies: Chemical Industry, WSH Council
ISO Tanker Work-at-Height
Scenario:
This work activity required the worker to climb-up and lay a hose to the top-opening
of the ISO Tanker. The worker accesses the top-opening via a ladder at the rear of
the ISO tanker. Current control measures include training, Safe Work Procedures
and the provision of a body harness
(of which the worker is not wearing) anchored to the top of the ISO tanker.
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Possible Solution
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Inert Blanketing of Head Space in Tanks
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Prevent Static Build Up in Tanks and Pipe Lines
Use Radar Gauge to Measure
Liquid Level
Operating Procedures
• Steps for each operating phase
• Operating limits & consequences of deviation
• Engineering and administrative controls for preventing exposures
• Controls needed for safe operation
• Permits required
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Permits
• Control non-routine activities conducted in potentially hazardous environmental
• Description of hazards
• Actions to be taken – before and after work, transition to normal operating mode
• Communication of relevant information
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Hot Work Permit• Issued for all hot work operations conducted on
or near a process
• Prevent ignition of flammable or combustible gases, liquids or vapours
• Welding, grinding, torch cutting, soldering, brazing & any activities that produces flames, sparks or excessive heat
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Hot Work Permit
• Document fire prevention and protection measures have been put in place prior to hot work commencement
• Indicate date(s) authorised for the hot work
• Identify the object on which hot work is to be performed
• Valid for 1 shift
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Hot Work Permit• Use flammable gas detector to check LEL, UEL
exceedances
• Remove all flammable or combustible materials within 35ft (about 12m) radius of hot work
• Cover with flame retardant materials
• Assign fire watch
• Fire extinguisher in area
• Compromised fire detection & protection system –smoke detector, sprinkler, alarms
• Communication
• Display of permit
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Source: Case Studies: Chemical Industry, WSH Council
FLASH FIRE DURING CHARGING OF FLAMMABLE POWDER
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Source: Case Studies: Chemical Industry, WSH Council
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Source: Case Studies: Chemical Industry, WSH Council
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Lock Out/Tag Out
• Prevents injuries or damage due to accidental release of stored energy
• ALL ENERGY SOURCES: Electrical, gravitational, mechanical, pneumatic, thermal and chemical
• Unexpected motion or release
• Permit or LOTO procedure
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Examples of LOTO Application
Lock Out/Tag Out
• De-energise equipment – unplug electrical connections, release pressurised lines, spring-loaded devices, filled chemicals
• Lock equipment, device, line to prevent re-activation
• Tag equipment, device
• Try to re-energise for verification
• More than 1 worker – use Gang Lock Device (HASP lock)
• 1 person, 1 key
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Confined Space Entry
• Called Vessel Entry (in textbook)
• Enclosed area with limited means of access
• Not for continuous occupation
• Has restricted natural ventilation
• Include tanks, manholes, pipes, pits and silos
• May also have risk of fire and explosion or engulfment by the material in vessel
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Examples
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Accident Cases Involving Confined Space
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Hazards in Confined Space• Insufficient oxygen
• Substances already present
– Residual petroleum vapour in storage tanks
– Contents not adequately purged
• Substances introduced during work processes
– Cleaning chemicals/solvents (e.g. acetone, trichloroethylene)
– Paint fumes (e.g. toluene, xylene)
• Substances agitated and released during entry –Sludge
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Hazards in Confined Space
• Flammable Substances introduced
– Cleaning chemicals
– Paint fumes
– Leakages from adjacent tanks/pipes
• Ignition sources introduced
– Welding/cutting operations
– Spark generation
– Static discharge
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Common Atmospheric Hazards
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Source: Confined Space Safety Guidebook for Supervisors and Workers, WSH Council
Confined Space Entry• Legal Requirements
• Identification/ record/ warning signs/ information of all confined spaces at the workplace
• Evaluation of need for entry
• Safe means of access to and exist from confined space;
• Safe practices for opening entrance of a confined space;
• Sufficient and suitable lighting for entry into or work
• Adequate ventilation to sustain life before entry and during work in a confined space
• Procedures and control of entry into a confined space including gas testing
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Confined Space Entry
• Confined space entry permit issue on daily basis
• Isolate equipment – LOTO
• Continuous monitoring of oxygen concentration >19.5%
• Confined space attendant
• Communications process
• Rescue procedure
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Confined Space Entry
Reading Permissible Levels
Oxygen ≥ 19.5 % Vol. to ≤ 23.5 % Vol.
Flammable gases and
vapours
≤ 10% Lower Explosive Limit
(LEL)
Toxic gases and vapours ≤ Permissible Exposure Limit
(PEL) values
Acceptable limits for the atmospheric test are:
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Confined Space Entry• Geometry of the space and physical properties of the gases -
different at different level
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Source: Technical Advisory on Working Safely in Confined Spaces, WSH Council
Confined Space Entry
• Ventilation for confined space – Space ventilated and tested prior to entry. Continuous ventilation to ensure contaminants do not build up to a dangerous level.
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Source: Technical Advisory on Working Safely in Confined Spaces, WSH Council
Confined Space Entry
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Going Beyond Compliance
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Zero Harm
VISION
ZERO
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Tutorial Questions• Questions 13-8 and 13-21
• Watch the 2 videos listed below. What recommendations can you give to prevent similar accidents from happening?
a) Dupont Hot Work Accident in 2012https://www.youtube.com/watch?v=PqskpvPejeU
b) Xcel Energy Company Confined Space Accident
https://www.youtube.com/watch?v=BeaX0IRjyd8
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Steel Pipes Dimensions - ANSI
Schedule 40
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Thank You