Confined Space Entry Procedure and Permit for Forging Facilities

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 requirements for safe entry into confined spaces at forging facilities, specifically addressing hydraulic press pits and forge furnaces. It applies to all employees, contractors, and visitors who may be required to enter a confined space at the facility. This procedure is designed to comply with all applicable safety regulations and standards related to confined space entry. The procedure includes guidelines for hazard identification, risk assessment, permit issuance, entry procedures, and emergency response.

2. Definitions

Confined Space A space that is large enough for an employee to enter, has limited or restricted means of entry or exit, and is not designed for continuous employee occupancy. [9]

Permit-Required Confined Space A confined space that contains or has the potential to contain a hazardous atmosphere, contains a material that has the potential for engulfing an entrant, has an internal configuration that could trap or asphyxiate an entrant, or contains any other recognized serious safety or health hazard. [8]

Entry Permit A written authorization that allows entry into a permit-required confined space, verifying that pre-entry procedures have been completed and the space is safe to enter. [3]

Attendant An individual stationed outside the confined space who monitors the entrants, maintains communication, and performs rescue duties as needed. [4]

Entrant A trained and authorized employee who is allowed to enter a confined space to perform work. [3]

3. Responsibilities

3.1 Supervisors

• Ensure that a confined space hazard assessment is conducted to identify all potential hazards within the space.
• Verify that all entrants, attendants, and entry supervisors are adequately trained and competent to perform their assigned duties.
• Ensure that a valid entry permit is completed and posted at the entrance of the confined space before entry.
• Provide all necessary equipment, including PPE, testing equipment, and rescue equipment, in good working order.
• Monitor work activities to ensure compliance with the SWP and permit requirements.

3.2 Workers

• Participate in required training programs and demonstrate competency in confined space entry procedures.
• Understand and follow the instructions outlined in the entry permit and this SWP.
• Use all required PPE and safety equipment correctly.
• Monitor the atmosphere within the confined space and report any changes or hazards to the attendant.
• Evacuate the confined space immediately if any unsafe conditions arise or upon notification by the attendant or supervisor.

3.3 Health and Safety Representative

• Participate in the development and review of the confined space entry program and this SWP.
• Conduct periodic audits of confined space entry operations to ensure compliance with safety regulations and the SWP.
• Investigate incidents and near misses related to confined space entry and recommend corrective actions.
• Provide guidance and support to supervisors and workers on confined space safety issues.

4. Potential Hazards and Risks

5. Personal Protective Equipment (PPE)

All personnel entering confined spaces must use appropriate personal protective equipment (PPE) to protect against potential hazards. PPE must be inspected before each use to ensure it is in good condition.

• Hard Hat: To protect against head injuries from falling objects or bumping into overhead structures. [1]
• Safety Glasses/Goggles: To protect against eye injuries from dust, debris, or chemical splashes. [1]
• Gloves: To protect against skin contact with chemicals, sharp objects, or hot surfaces. The type of glove must be appropriate for the specific hazards present. [1]
• Respiratory Protection: A respirator (air-purifying or supplied-air) to protect against inhalation of hazardous gases, vapors, or dusts. The type of respirator must be appropriate for the specific hazards present. [1]
• Protective Clothing: Appropriate clothing to protect against skin contact with chemicals, hot surfaces, or other hazards. This may include coveralls, aprons, or specialized suits. [11]

Respirators: Inspect for damage and ensure a proper fit. Clean and sanitize after each use. Store in a clean, dry place. Harnesses and Lifelines: Inspect for fraying, cuts, or other damage. Ensure buckles and D-rings are in good working order. Clean with mild soap and water. Gloves: Inspect for punctures, tears, or chemical damage. Replace as needed. Eye Protection: Inspect for cracks or scratches. Clean with appropriate lens cleaner.

6. Equipment and Tools

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

• Gas Monitor: A calibrated multi-gas meter capable of measuring oxygen levels, flammable gases, and toxic contaminants. The monitor must have audible and visual alarms. [11]
• Ventilation Equipment: A portable blower or fan to provide fresh air ventilation to the confined space. The equipment must be explosion-proof if flammable gases may be present. [10]
• Retrieval System: A safety harness and lifeline for each entrant, along with a winch or tripod for retrieval in case of emergency. The system must be capable of supporting the weight of the entrant. [11]
• Communication Device: A two-way radio or other communication device to maintain constant contact between entrants and the attendant. [1]
• Explosion-Proof Lighting: Portable lighting that is approved for use in hazardous atmospheres. [11]

Gas Monitors: Calibrate before each use and verify sensors are functioning correctly. Inspect for damage and ensure the battery is fully charged. Ventilation Equipment: Inspect hoses and connections for leaks or damage. Ensure the fan is operating correctly and providing adequate airflow. Retrieval Systems: Inspect the lifeline for fraying or damage. Ensure the winch and braking mechanism are functioning correctly. Lighting: Use explosion-proof lighting and inspect for damage to cords and bulbs.

7. Pre-Job Requirements

7.1 Training and Competency

Training and Competency: All employees involved in confined space entry must receive comprehensive training on the hazards of confined spaces, entry procedures, use of PPE, and emergency response. Training must be conducted by a qualified instructor and documented. Refresher training must be conducted at least annually or whenever there are changes in procedures or equipment. [3]

7.2 Pre-Job Briefing

Pre-Job Briefing: A pre-job briefing must be conducted before each entry to discuss the hazards, control measures, entry procedures, and emergency plan. All entrants, attendants, and the entry supervisor must participate in the briefing. The briefing must be documented. [1]

7.3 Work Area Preparation

Work Area Preparation: Before entry, the work area around the confined space must be cleared of obstructions and hazards. Warning signs and barriers must be erected to prevent unauthorized entry. The area must be adequately lit, and ventilation equipment must be set up to provide fresh air. [2]

8. Safe Work Procedure Steps

1. 1. Hazard Assessment: A competent person must conduct a hazard assessment to identify all potential hazards associated with the confined space. This includes atmospheric hazards, physical hazards, and any other potential dangers. [12]
2. 2. Permit Issuance: An entry permit must be completed and signed by the entry supervisor before any entry is allowed. The permit must include the purpose of entry, identified hazards, control measures, required PPE, and emergency procedures. The permit must be posted at the entrance of the confined space. [3]
3. 3. Atmospheric Testing: Before entry, the atmosphere within the confined space must be tested for oxygen levels, flammable gases, and toxic contaminants. Testing must be conducted using calibrated direct-reading instruments. The results must be recorded on the entry permit. [7]
4. 4. Ventilation: If atmospheric hazards are identified, the confined space must be ventilated to remove contaminants and maintain a safe atmosphere. Ventilation must continue throughout the entry. [10]
5. 5. Lockout/Tagout: All energy sources that could pose a hazard to entrants must be locked out and tagged out before entry. This includes electrical, mechanical, hydraulic, and pneumatic energy sources. [1]
6. 6. Entry: Entrants must use a safety harness and lifeline when entering the confined space. The lifeline must be attended by the attendant outside the space. Entrants must continuously monitor the atmosphere and communicate with the attendant. [10]
7. 7. Attendant Duties: The attendant must remain outside the confined space at all times while entrants are inside. The attendant must monitor the entrants, maintain communication, and be prepared to initiate rescue procedures if necessary. The attendant must not enter the confined space unless properly trained and equipped for rescue. [2]
8. 8. Continuous Monitoring: The atmosphere within the confined space must be continuously monitored during entry to ensure that hazards do not develop. If any hazardous conditions are detected, all entrants must evacuate immediately. [1]
9. 9. Emergency Procedures: In the event of an emergency, the attendant must immediately notify emergency services and initiate rescue procedures. All entrants must be evacuated from the confined space. First aid and CPR must be administered if necessary. [5]
10. 10. Permit Termination: Once the work is completed and all entrants have exited the confined space, the entry permit must be terminated by the entry supervisor. The permit must be reviewed and filed for one year. [3]

9. Precautions and Safety Measures

• Never enter a confined space without a valid entry permit. [2]
• Always test the atmosphere before entry and continuously monitor it during entry. [4]
• Use appropriate PPE, including respiratory protection, hearing protection, and protective clothing. [1]
• Ensure proper ventilation to maintain a safe atmosphere. [4]
• Maintain constant communication between entrants and the attendant. [4]

10. Emergency Procedures

10.1 General Emergency Response

In the event of an emergency, such as a hazardous atmosphere alarm, entrant injury, or equipment failure, the following steps shall be taken: 1. Evacuate the confined space immediately. 2. The attendant shall immediately notify the emergency services. 3. The attendant shall provide first aid and CPR if trained to do so. 4. Keep unauthorized personnel away from the confined space. 5. Follow the instructions of the emergency services personnel upon arrival.

10.2 Specific Emergency Scenarios

• Hazardous Atmosphere Alarm: If the gas monitor alarms, all entrants must evacuate immediately. The space must be re-evaluated, and the source of the hazardous atmosphere identified and controlled before re-entry. Ventilation must be increased, and the atmosphere re-tested.
• Entrant Injury or Illness: The attendant must immediately call for emergency services and provide first aid. If safe, the entrant should be removed from the space using retrieval equipment. The attendant should never enter the space unless properly trained and equipped for rescue.
• Equipment Failure: If any equipment fails (e.g., ventilation, gas monitor), all entrants must evacuate immediately. The equipment must be repaired or replaced before re-entry. The supervisor must reassess the space and permit.

11. Incident Reporting and Investigation

All incidents, including near misses and injuries, must be reported to the supervisor immediately. A written report must be submitted within 24 hours of the incident. The report should include a detailed description of the incident, the cause of the incident, and any corrective actions taken.

A thorough investigation must be conducted to determine the root cause of the incident. The investigation team should include representatives from safety, supervision, and the workforce. The investigation findings must be documented, and corrective actions implemented to prevent recurrence.

Approved by: [NAME AND POSITION]

Date: [APPROVAL DATE]

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