Valve Replacement in Confined Space Underground Vessel

Document Number: [SWP-NUMBER]

Revision Date: [DATE]

Next Review Date: [NEXT REVIEW DATE]

Department: [DEPARTMENT NAME]

1. Scope

This Safe Work Procedure (SWP) outlines the safety requirements and procedures for the replacement of valves within confined space underground vessels. It applies to all personnel involved in the valve replacement process, including employees, contractors, and supervisors. This SWP covers all aspects of the task, from pre-entry preparation to post-replacement procedures. It is designed to minimize risks associated with confined space entry, hazardous materials, and mechanical operations. This SWP does not cover live tapping or hot work on pressurized systems; a separate procedure is required for those tasks.

2. Definitions

Confined Space A space that is large enough and so configured that an employee can bodily enter and perform assigned work, and has limited or restricted means for entry or exit, and is not designed for continuous employee occupancy. Lockout/Tagout (LOTO) The process of isolating a system from all energy sources. Confined Space Entry Permit A written plan detailing the procedures and equipment necessary for safe entry into a confined space. Hazard Assessment The identification and evaluation of potential hazards associated with a task. Control Measures Measures taken to eliminate or reduce the risk associated with a hazard.

3. Responsibilities

3.1 Supervisors

Ensure all workers are trained and competent to perform the task.
Conduct pre-job briefings and hazard assessments with the team.
Verify that all required PPE is available and in good condition.
Monitor work progress and ensure adherence to safety procedures.
Address any safety concerns raised by workers promptly.
Ensure all equipment is inspected and in safe working order.

3.2 Workers

Adhere to all safety procedures and guidelines outlined in this SWP.
Participate in pre-job briefings and hazard assessments.
Use required PPE correctly and report any defects.
Report any hazards or unsafe conditions immediately to the supervisor.
Follow all instructions and procedures as trained.
Do not proceed with the task if unsure about any aspect of the procedure.

3.3 Health and Safety Representative

Participate in the development and review of this SWP.
Conduct regular site inspections to ensure compliance with safety procedures.
Investigate incidents and recommend corrective actions.
Provide guidance and support to workers and supervisors on safety matters.
Promote a positive safety culture within the workplace.

4. Potential Hazards and Risks

Hazard	Risk	Control Measures
Hazardous Atmosphere (e.g., oxygen deficiency, toxic gases)	Asphyxiation, poisoning, explosion	1. Conduct atmospheric testing before entry and continuously monitor. 2. Provide adequate ventilation to maintain safe oxygen levels and prevent accumulation of hazardous gases. 3. Use air-supplied respirators or SCBAs. 4. Implement a buddy system and ensure proper communication.
Uncontrolled Energy Release (electrical, mechanical, hydraulic)	Electrocution, crushing, burns	1. Implement lockout/tagout procedures to isolate all energy sources. 2. Verify isolation with testing before starting work. 3. Use non-sparking tools in potentially explosive atmospheres.
Falls from Heights	Serious injury, death	1. Ensure proper training and use of fall protection equipment (e.g., harnesses, lanyards). 2. Use guardrails or covers on open holes and excavations. 3. Maintain three points of contact when climbing ladders or stairs.
Poor Visibility	Slips, trips, falls, struck-by injuries	1. Provide proper lighting inside the confined space. 2. Use reflective clothing to increase visibility. 3. Ensure clear communication between workers inside and outside the confined space.
Manual Handling of Heavy Valves	Strains, sprains, back injuries	1. Use proper lifting techniques and equipment (e.g., hoists, slings). 2. Ensure adequate space for movement and lifting. 3. Provide training on manual handling and lifting procedures.
Exposure to Hazardous Materials (e.g., process chemicals)	Skin irritation, chemical burns, respiratory problems	1. Provide appropriate PPE (e.g., chemical-resistant gloves, eye protection). 2. Ensure proper ventilation and containment of spills. 3. Provide training on SDS and chemical handling procedures.
Electrical Hazards	Electrocution, burns	1. Use properly insulated tools and equipment. 2. Maintain safe distances from electrical sources. 3. Inspect electrical cords and equipment for damage before use.
Confined Space Entry Hazards	Asphyxiation, entrapment, exposure to hazardous substances	1. Implement a permit-required confined space entry program. 2. Ensure all entrants are trained and authorized. 3. Provide continuous monitoring and communication.

5. Personal Protective Equipment (PPE)

All personnel involved in valve replacement in confined spaces must wear appropriate personal protective equipment (PPE) to minimize the risk of injury or exposure to hazards.

Air-Supplied Respirator or SCBA: Provides respiratory protection in hazardous atmospheres. A positive pressure, full-facepiece self-contained breathing apparatus (SCBA), or positive pressure supplied air respirator with escape SCBA (NIOSH approved) may be required. [1]
Hard Hat: Protects the head from impact and falling objects. [1]
Safety Glasses or Goggles: Protects the eyes from chemical splashes and debris. [1]
Chemical-Resistant Gloves: Protects the hands from chemical exposure and cuts. [1]
Steel-Toed Boots: Protects the feet from impact and chemical exposure. Boots, outer, chemical-resistant steel toe and shank may be required. [1]
Chemical-Resistant Coveralls: Protects the body from chemical exposure. Hooded chemical-resistant clothing (overalls and long-sleeved jacket; coveralls; one or two-piece chemical-splash suit; disposable chemical-resistant overalls) may be required. [1]

1. Inspect all PPE before each use for damage or defects. 2. Clean and maintain PPE according to manufacturer's instructions. 3. Store PPE in a clean, dry place when not in use. 4. Replace damaged or defective PPE immediately.

6. Equipment and Tools

All equipment and tools must be inspected before use to ensure they are in good working condition. Any defective equipment must be removed from service immediately.

Multi-Gas Meter: Used to measure oxygen levels, flammable gases, and toxic substances in the confined space atmosphere.
Ventilation Equipment: Provides fresh air to workers inside the confined space.
Lockout/Tagout Devices: Used to isolate energy sources and prevent accidental start-up of equipment.
Explosion-Proof Lighting: Provides illumination inside the confined space.
Hand Tools (wrenches, screwdrivers, etc.): Used for cutting, tightening, and loosening bolts and fasteners.
Hoisting Equipment (e.g., chain hoist, come-along): Used for lifting and moving heavy valves.

1. Inspect all tools and equipment for damage or defects before each use. 2. Ensure power tools have proper grounding and GFCI protection. 3. Check all hoses and connections for leaks or damage. 4. Maintain equipment according to manufacturer's recommendations. 5. Remove any damaged or defective equipment from service immediately.

7. Pre-Job Requirements

7.1 Training and Competency

Training and Competency: All personnel must be trained and competent in confined space entry, lockout/tagout procedures, and the use of required PPE. Training records must be available for review.

7.2 Pre-Job Briefing

Pre-Job Briefing: A pre-job briefing must be conducted with all personnel involved to discuss the scope of work, potential hazards, and safety procedures. All workers must acknowledge their understanding of the plan.

7.3 Work Area Preparation

Work Area Preparation: The work area must be properly prepared before starting the valve replacement. This includes:

Isolating and de-energizing the system using lockout/tagout procedures.
Ventilating the confined space to ensure a safe atmosphere.
Setting up proper lighting and ventilation equipment.
Ensuring all necessary tools and equipment are available and in good working condition.

8. Safe Work Procedure Steps

Obtain Confined Space Entry Permit: Obtain a confined space entry permit from the authorized person. Ensure all sections of the permit are completed and signed.
Isolate and Lockout/Tagout the Valve: Isolate the valve to be replaced by closing upstream and downstream valves. Implement lockout/tagout procedures to prevent accidental opening of valves.
Depressurize the System: Depressurize the isolated section of the system. Verify that the pressure is zero using a calibrated pressure gauge.
Disconnect the Valve: Disconnect the valve from the piping system. Use appropriate tools and techniques to avoid damage to the piping.
Remove the Old Valve: Remove the old valve from the confined space. Use proper lifting techniques and equipment to avoid strains and sprains.
Inspect the New Valve: Inspect the new valve for any damage or defects. Ensure that it is the correct type and size for the application.
Install the New Valve: Install the new valve in the piping system. Use appropriate gaskets and fasteners to ensure a leak-tight seal.
Connect the Valve: Connect the valve to the piping system. Use appropriate tools and techniques to avoid damage to the piping.
Restore System Operation: Remove lockout/tagout devices and restore the system to normal operation.
Test for Leaks: Test the new valve for leaks. Use a soap solution or other leak detection method to identify any leaks.
Document the Valve Replacement: Document the valve replacement, including the date, time, valve type, and any issues encountered.
Remove Equipment and Clean the Area: Remove all tools and equipment from the confined space. Ensure the area is clean and free of hazards.

9. Precautions and Safety Measures

Ensure continuous atmospheric monitoring for oxygen levels, flammable gases, and toxic substances. - Use calibrated multi-gas meters and set alarms for unsafe conditions.
Implement a buddy system to ensure that workers are always in visual or verbal contact with each other. - Each worker should be responsible for monitoring their buddy's condition and safety.
Use appropriate ventilation to maintain a safe atmosphere inside the confined space. - Ensure ventilation equipment is properly sized and positioned to provide adequate air circulation.
Implement lockout/tagout procedures to isolate all energy sources and prevent accidental start-up of equipment. - Verify isolation with testing before starting work.
Provide adequate lighting to ensure good visibility inside the confined space. - Use explosion-proof lighting fixtures to prevent ignition of flammable gases.

10. Emergency Procedures

10.1 General Emergency Response

In the event of an emergency, follow these general steps: 1. Assess the situation and ensure your own safety. 2. Activate the emergency alarm system. 3. Evacuate the area if necessary. 4. Provide first aid if trained and safe to do so. 5. Contact emergency services and provide them with accurate information. 6. Follow the instructions of emergency responders.

10.2 Specific Emergency Scenarios

Exposure to Hazardous Atmosphere: 1. Activate the emergency alarm. 2. Evacuate the confined space immediately. 3. Administer oxygen if available and trained. 4. Contact emergency services and provide details of the exposure.
Worker Injury or Incapacitation: 1. Activate the emergency alarm. 2. Evacuate the confined space immediately. 3. Provide first aid and CPR if trained. 4. Contact emergency services.
Fire or Explosion: 1. Activate the emergency alarm. 2. Evacuate the confined space immediately. 3. Use fire extinguishers if trained and safe to do so. 4. Contact emergency services.

10.3 Emergency Contact Information

In case of emergency, contact the following: Emergency Services: 911 Site Supervisor: [Insert Contact Number] Safety Officer: [Insert Contact Number]

11. Incident Reporting and Investigation

1. Report all incidents, including near misses, to the supervisor immediately. 2. Complete an incident report form with all relevant details. 3. Submit the incident report to the safety department within 24 hours.

1. The safety department will investigate all reported incidents. 2. The investigation team will gather information, interview witnesses, and analyze the root causes of the incident. 3. A written report will be prepared with findings and recommendations for corrective actions. 4. Implement corrective actions to prevent recurrence.

Approved by: [NAME AND POSITION]

Date: [APPROVAL DATE]