isolation, lockout and clearance to … and tag/isolation, lockout... · to ensure that all risks...

ISOLATION, LOCKOUT,

CLEARANCE TO WORK

AND CONFINED SPACE

TRAINING FOR ANGLO

AMERICAN PLATINUM

SMELTERS

ISOLATION & LOCKOUT

LO1 (1)

The AIM of the Isolation, Lock out and clearance to work procedure :

To ensure that all risks to Health and Safety

arising from biological, chemical and / or energy hazards are safely controlled while work is been carried out on machinery by ensuring that such hazards are safely isolated and locked out while such work is being carried out.

ISOLATION & LOCKOUT

The result of insufficient Equipment Safeguarding and Isolation and

Lockout Standards and Procedures.

ISOLATION & LOCKOUT

This person failed to follow the Isolation

and Lock out procedure

ISOLATION & LOCKOUTGOLDEN RULES OF LOCK OUT

1. Only persons who have been trained

and found competent, may take part

in Isolation, Lockout and Clearance to

work operations

ISOLATION & LOCKOUT

GOLDEN RULES OF LOCK OUT

2. Always test to ensure that Isolation,

Lock-Out or Clearance to work is

effective before starting to work

ISOLATION & LOCKOUT


3. Good communication must always

convey awareness to all the team

members

ISOLATION & LOCKOUT


4. When ever you are in doubt,

never hesitate to ask

ISOLATION & LOCKOUT


5 Remember no work is so

Important and Urgent that it

should be conducted in an

unsafe manner.

ISOLATION & LOCKOUT

Definitions

Hazard

A source of or exposure to danger

(MHSA).

IS THIS LION A HAZARD?

ISOLATION & LOCKOUT

The hazards include but not limited to:

Machinery drive systems

Electrical energy

Potential Energy eg. due to gravitational force

Kinetic Energy due to moving Machines, as well as Air, Gas or Liquid flow / movement / displacement

ISOLATION & LOCKOUT

Hazards (cont1)

Stored Energy as it applies to:

Rotating Equip. Eg. Flywheels

Elastic strain. Eg. steel springs, disks/

diaphragms.

Substances under pressure.

ISOLATION & LOCKOUT

Hazards (cont2)

Hazardous Substances.

Temperature Extremes. (-175dig C to

+1600dig C)

ISOLATION & LOCKOUT

Summery of Energy Sources that may be

present in Identified Hazards but not

limited to these.

Electricity

Gravity

Hydraulic Pressure

Water Pressure

Air Pressure

Mechanical

Chemical

Noise

Thermal

Radiation

ISOLATION & LOCKOUT

Definitions

Risk

The likelihood that

occupational injury or harm to

persons will occur (MHSA).

ISOLATION & LOCKOUT

Definitions

Machinery

For the purpose of this procedure

machinery means; any machinery,

plant, equipment, installation,

structure, tank, pit, apparatus

and/or place.

ISOLATION & LOCKOUT

Definitions

Works Order

A written order calling for work,

issued in accordance with a

procedure for the issuing of

Works Orders, that is approved

and implemented by the

Responsible Manager and

Engineer

ISOLATION & LOCKOUT

Definitions

Clearance to Work

A Permit, issued in accordance with an approved format by the Responsible Operator, allowing work (called for by a Works Order) to be carried out.

ISOLATION & LOCKOUT

Definitions

De-energise

Preventing inadvertent contact

with or exposure to biological,

chemical and/or energy hazards by

effectively isolating such hazards.

ISOLATION & LOCKOUT

Definition

Isolate (to de-energise)

To Isolate is the physically removal of any connection or means to

supply of

any form of energyto equipment in order to make

excitation of such equipment impossible. (AFRS)

ISOLATION & LOCKOUT

Definitions

Isolation Point

The Point/Place at which a designated Isolation Device is installed for equipment that must be Isolated and Locked-Out. (refer to AFRS).

Include Electrical, Mechanical and Physical Isolation

ISOLATION & LOCKOUT

Definitions

Isolation Device

The designated Device used to

Isolate equipment that must be

Isolated and Locked-Out.

ISOLATION & LOCKOUT

Definition

Locking Device

A key operated padlock or other type of

key operated Locking Device engaged

onto/into an Isolation Device in its

Isolating position to prevent

inadvertent de-Isolation (AFRS)

Provided that: combination type

Locking Devices are not permitted.

ISOLATION & LOCKOUT

DefinitionsDanger Tag

A personal Isolation

Tag secured to a

Personal Isolation

Padlock (Service

Padlock) at the

Point of Isolation

when an Isolation is

in place.

DA N G E R

THIS

ISOLATION DEVICE

- Circuit Breaker - Valve – Gate -

- Other Locked Device-

MUST NOT BE

OPERATEDSEE OTHER SIDE

DA N G E R

THIS:…………………………………………

MUST NOT BE OPERATED

REASON………………………………………

…………………………………………….……

…………………………………………….……

………………………………………….………

………………………………………….………DATE:…………….. Phone No.:……...……...……..

Name:…………………..…Signed:…...…..………..

CONFIRMATION OF WORK COMPLETED

………………………….. ……….………….………

Artisan/Person - (RESPONSIBLE) - Operator

THIS DANGER TAG HAS BEEN FIXED IN

ACCORDANCE WITH THE PROCEDURE

FOR ISOLATION, LOCK-OUT AND

CLEARANCE TO WORK – ONLY THE

UNDERSIGNED MAY REMOVE THE TAG

SMELTER……………………………...……..

SECTION……………………………………..

Reinforced Engagement

Eyes - 8mm Dia.

ISOLATION & LOCKOUT

Definitions

Isolation Record Book

A register which provides an

overview of the state of Isolation,

Lock-Out and Permits to Work at

any time (refer to AFRS).

ISOLATION & LOCKOUT

Definitions

Lock-out

The engaging of locks into/onto the Isolation Device/s of machinery to the extent that the hazards presented by the normal operation of such machinery are Isolated and Locked-Out while access is granted to such machinery in order to carry out work as is called for by a Works Order safely.

Certificate of Isolation and Lock-Out

Training

The certificate of training issued to a person

who becomes competent to take part in

Isolating and Locking-Out operations by

virtue of training received. Provided that: the

training received must pertain specifically to

the duties of a Responsible Operator and a

Responsible Artisan/Person in each case.

ISOLATION & LOCKOUT

Definitions

ISOLATION & LOCKOUT

WORK ORDERS

WORKS ORDER ARTISAN/PERSON

is assigned responsibility

to ensure that work is carried out

RESPONSIBLE ARTISAN/PERSON

carries out HIRA for work

RESPONSIBLE ARTISAN/PERSON

Presents Works order to Responsible

Operator in Control Room

Responsible Operator Checks whether equipment is already isolated for compatibility of risk control requirements

Responsible Operator may point out additional hazards and call for additional risk controls for the work

Responsible Operator validates Isolation and Lock-Out Competency of Responsible Artisan/Person

1 2 3

4

ISOLATION & LOCKOUTWORK ORDERS

LEARNING OUTCOME 3.1

PERSONS AUTHORISED TO ISOLATE AND LOCK OUT PLANT

AND EQUIPMENT


PERSONS AUTHORISED TO ISOLATE

AND LOCK OUT PLANT AND

EQUIPMENT

RESPONSEBLE ARTISAN / PERSON

What is this person’s responsibilities with regards to Isolation and

lock out.

Go to page 6, 8,11 and 12 of your LG


PERSONS AUTHORISED TO ISOLATE

AND LOCK OUT PLANT AND

EQUIPMENT

RESPONSEBLE OPERATOR

What is this person’s responsibilities with

regards to Isolation and lock out.

Go to page 5, 6, 7,11 and 12 of your LG



The Nature of work for which a work order

must be generated

ISOLATION & LOCKOUT

WORK ORDERS

An approved Works Order (job

card) must be generated for all

work before any person is

assigned responsibility to

ensure that the work is carried

out.

ISOLATION & LOCKOUT

WHEN DO YOU NEED A WORKS

ORDER?


The aforementioned work includes:

(i) Maintenance and Repair Work

(ii) Installation and commissioning

work

(iii) Building and construction work


(iv) Any other work for which a routine operating procedure has not been developed including (but not restricted to) work necessitating the temporary removal of guarding, cleaning, washing down, the removal / disposal of spillage, rubble, slurry or residue.


Provided that :

All work for which a works

order is generated must be

considered non routine work in

terms of AFRS requirements

for non routine work.


Work for which a Works Order

(job card) need not be

generated


(i) The normal operation of

machinery where such work

does not require access to

moving machinery or other

normally restricted areas,

and for which:


A safe operating procedure has

been developed


All persons required to operate the

machinery have been trained on

the aforementioned safe operating

procedure and are conversant with

the safety requirements of the

procedure.


Routine work that requires local isolation of moving machinery in order to gain safe operational access to such machinery and for which; the aforementioned isolation and access is part of a routine operating procedure that has been subjected to a HIRA and approved by the Responsible Engineer and Responsible Manager.


i.e.

Loading clay into a furnace mud-

gun,

Cleaning metal from continuous

caster links,

Cleaning in the Lab Robot Circle


Provided that:

(a) unless otherwise permitted by

the Responsible Engineer in

writing, subject to such conditions

as he / she may require, a record of

Isolation and Locking out must still

be made in the IRB


(b) the aforementioned isolation

process does not require the

isolation of more than one energy

source


(c) Work, responsibly called

for, by threatening

emergencies.


(d) Supervisory and/or

administrative work that

is routine and functionally

safe when carried out.



PRE WORK HIRA


PRE WORK HIRA

What does HIRA stands for?

H HAZARD

I IDENTIFICATION

R RISK

A ASSESSMENT


PRE WORK HIRA

WHO MUST DO THE PRE WORK HIRA?


PRE WORK HIRA

THE RESPONSEBLE ARTISAN /

PERSON MUST PRESENT THE

WORKS ORDER WITH THE

COMPLETED HIRA TO THE

RESPONSEBLE OPERATOR


LEARNING OUTCOME 4

RECORDING OF ISOLATION, LOCK OUT

AND CLEARANCE TO WORK DETAILS

IN THE ISOLATION RECORD BOOK

(IRB)


ISOLATION RECORD BOOK (pg 30 of LG)

WHAT IS THE PURPOSE OF THE IRB?

Go to the definitions pg 5


Isolation Record Book

A register which provides an

overview of the state of Isolation,

Lock-Out and Permits to Work at

any time (refer to AFRS).


WORK ORDER Number:………………

EQUIPMENT ISOLATED

(Include Equipment Number)

ISOLATION POINT AND DEVICE

(Include Equipment Number)

ISOLATION

TEST METHOD

RESPONSIBLE OPERATOR

(i) Name (ii) Co. Number

(ii) Lock Out Certification No.

RESPONSIBLE

ARTISAN/PERSON

(i) Name (ii) Co. Number

(ii) Lock Out Certification No.

MASTER PADLOCK NUMBER……………………………………………….

Engaged at time of Isolation for additional work in progress: YES NO

SERVICE PADLOCK

Number: …………...……...…...………...

MULTIPLE PADLOCK CALLIPER NUMBER (If Required)…………………...……………..

Engaged at time of Isolation for additional work in progress: YES NO N/A

Padlock Engagement Details Confirmed Correct :- Responsible Operator (Signed) ….……...……….…….………..…….....…. Responsible Person/Artisan (Signed) …………….……..……………….…..…………………

Service Padlock Return Record (After Clearance to Work Cancellation) Responsible Operator (Signed) …………..…….…….…...……….……….

Date: ……………… Time: ……………… Responsible Person/Artisan (Signed) ……………..…………...…....……………

Master Padlock

Returned

YesYes

NoNo

Multiple Padlock

Caliper Returned

Yes

NoN/A

REMOVAL AUTHORISED BY ENGINEER N/A YES

Reason:…………………….….…..……….

…………………………..………...…….


Details to be recorded on the IRB#1

As a minimum, the following records pertaining to each Isolation process must be made:

Works Order number

Name of each person involved

Isolation and Lock-Out Competency number (Lock-Out Licence number)

Date

Time


Details to be recorded on the IRB#2

Plant/equipment being Isolated (including equipment number)

Isolation Point used

Identification number of Locking Devices (Lock-Out Padlocks) used for Isolating.

Test/Check method used to ensure that effective isolation has been carried out.

Each person must clear the isolation record when the task is completed by entering his/her name (Print), date and time.

ISOLATION & LOCKOUT

LOCK-OUT PADLOCKS MASTER PADLOCK

Responsible Operator takes Responsible possession

SERVICE PADLOCK

Issued to Responsible Artisan/Person - together with Danger Tag

Details are recorded and signed as such in the Isolation Record Book (IRB)

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3

ISOLATION & LOCKOUTWORK ORDER NUMBERS

Works Order number must be

recorded on the IRB, because it is

the proof that the responsible

Artisan /Person are authorised and

assigned the responsibility by the

Responsible Engineer to perform

the work.

ISOLATION & LOCKOUTEMERGENCY WORK ORDER

NUMBERS

In an event where the responsible artisan / person had to perform emergency repair or maintenance work and the SAP system is off line an emergency Work Order must be obtained as per the respective Smelter’s internal procedure. This emergency Work Order must be recorded in the space provided on the IRB form.

ISOLATION & LOCKOUT

ISOLATION & LOCKOUT

ISOLATION AND LOCK-OUTDESIGNATED ISOLATION DEVICE

is used to Isolate equipment/Machine

MASTER PADLOCK: Engaged into

Isolation Device By Responsible

Operator who Retains Key

SERVICE PADLOCK: Engaged into Isolation

Device By Responsible Artisan/Person (together

with filled in Danger Tag) who Retains Key

ISOLATION AND LOCK OUT IS VERIFIED BY TEST

If there is no facility for testing Isolation and Lock-Out – Electrician is called to disconnect power supply before engaging Padlocks

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ISOLATION & LOCKOUT

ISOLATION & LOCKOUTPlease take note

It is important that you understand why the following permits may also be required:

HOT WORK

SCAFFOLD

CONFINED SPACE OR VESSEL ENTRY

HAZARDOUS SUBSTANCE ISOLATION

RADIO-ACTIVE SOURCE ISOLATION

STANDBY POWER ISOLATION

EXCAVATION

WORKING AT HEIGHTS.

FREQUENT ISOLATION AND ACCESS

ISOLATION & LOCKOUTHOT WORK IN CONFINED SPACES

Isolation code sec 24.2.6 (iii)

Cutting torches, heating torches and/or

any other equipment which uses

oxygen, flammable gas and/or a

flammable substance must be

removed, complete with supply hoses,

from a confined space when not being

used.

ISOLATION & LOCKOUTHOT WORK IN CONFINED SPACES

As far as is reasonably practicable

heating or cutting torches must not be ignited inside the confined space and effective controls must be in place to prevent an inadvertent and/or uncontrolled release of oxygen, acetylene, or any other flammable gas / substance into the confined space at any time.

ISOLATION & LOCKOUT

ISOLATION AND LOCK-OUT CANCELLATIONRESPONSIBLE ARTISAN/PERSON

Removes Service Padlock together with Danger Tag

from Isolation Device and cancels Danger Tag


(i) Takes possession of cancelled Danger Tag

(ii) Removes Master Padlock From Isolation Device


Supervises running tests

according to safe operating procedure


OR

1 2 3

4

Orders Isolation and Lock-Out to be carried out for

correction of defects (revealed by running test)

and

re-issues Clearance to Work Permit accordingly

Returns Master and Service Padlocks to Cabinet/s

Ensures Isolation and Lock-Out Cancellation is

entered and signed off in IRB / destroys Danger Tag

Allows equipment/machine to be operated

ISOLATION & LOCKOUT

Key hand over Procedure

ISOLATION & LOCKOUT

Stand by Power Isolation

Hot work

Confined Space

Working at Height

Communication in case of any Indecision

Who got the final say with plant safety?

ISOLATION & LOCKOUT

Shift hand over procedure

Isolation and Lock out of Trailing Cables

Isolation of Equipment with out an

Isolating Panel

Confined Space /

High Risk

Locations

Confined Space / High Risk

Location

A Confined Space or High Risk Location Entry

Permit is required before entry (for work) is

allowed into any High Risk Location.

(Issued by the Responsible Operator but only

after the atmosphere has been

declared safe for entry by the Occupational

Hygiene Technologist)

Because,


LocationThere may not been sufficient oxygen-

Solid or particulate material may fall-

It may contain water or slurry-

You can fall due to slipperiness and inadequate support-

May contain poisonous fumes or gasses-

There may be explosive or flammable gasses or substances present-

It may be to hot or to cold inside-


Location

• The Responsible Operator must ensure

that the Responsible Occupational

Hygienist (or another person to whom this

responsibility has been delegated in

writing) has declared the atmosphere in

the aforementioned Confined Space or

High Risk Location safe for entry.

Authorisation to declare the atmosphere of a Specific Confined Space or

High Risk Location Safe for Entry

Smelter Operation:……………………………………. Having Received the necessary theoretical and Practical Training……………………………………… Is hereby authorised to declare the Atmosphere in the following Confined Space/s or High Risk Location/s safe for entry: …………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… Instruments that the authorised person has been found competent to use:…………………………… …………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… This authorisation includes / does not include declaring an atmosphere safe to conduct Hot Work (See Section 9.5 of ALLSM-ALL-HLH-PRO-0003) Name: …………………….…. Signature………………… Date:…………… Responsible Occupational Hygienist Name: …………………….…. Signature………………… Date:…………… Responsible Engineer Name: …………………….…. Signature………………… Date:…………… Production Manager. I hereby confirm and accept the above authorisation: Name: …………………….…. Signature………………… Date:…………… Occupation:……………………………………………………………………..


Location

There may also be other Hazards inside

confined space or High Risk Location

there fore the Engineering

Foreman/Supervisor in charge is

required to facilitate a HIRA before

entry is allowed into any Confined or

High Risk Location.


Location

There should always be a sign at

the entrance to a Confined Space

or High Risk Location warning

people to this effect.


LocationDANGER

CONFINED SPACE

NO ENTRY WITHOUT WRITTEN PERMISSION

THIS CONFINED SPACE HAS THE FOLLOWING

HAZARDS

DANGER

HIGH RISK LOCATION

NO ENTRY WITHOUT WRITTEN PERMISSION

THIS HIGH RISK LOCATION HAS THE FOLLOWING

HAZARDS

CONFINED SPACE & HIGH RISK LOCATION ENTRY PERMIT PROCESSResponsible Artisan/Person receives Works Order to carry out work in a Confined Space or High Risk Location.

Responsible Artisan/Person conducts Pre-Work HIRA and presents same to Responsible Operator in control room.

Responsible Operator directs and oversees Isolation, makes appropriate records in Isolation Record Book.

-All vessel inlet/outlet valves to be closed and locked with barrier spades fitted between designated flanges-

Where atmospheric testing/monitoring is required before/after entry, the Responsible Operator contacts the ROH (or other person who has been designated in writing) to measure and asses thermal and/or other other atmospheric exposure levels inside the Confined Space or High Risk Location.

If Satisfied, the ROH or other person designated to measure and asses atmosphere exposure levels fills in the “ATMOSPHERE SAFE FOR ENTRY” declaration if the atmosphere is safe for entry in order for the work to be carried out.

A copy of the “ATMOSPHERE SAFE FOR ENTRY” declaration is displayed at each permitted entry into the Confined Space or High Risk Location and a copy is retained and filed by the Responsible Operator as proof that the Confined Space or High Risk Location has been declared safe for entry.

The ROH or other person designated to measure and asses atmosphere exposure levels may declare the atmosphere unsafe for entry (by ticking the allocated block in the Atmosphere Safe/Unsafe Declaration) if exposure levels are found to be too high and presents this declaration to the Responsible Operator for filing.

The ROH or other person designated to measure and asses atmosphere exposure levels may call for such additional measures to be taken as he/she may require and/or such exposure monitoring measures to be taken as are necessary for the atmosphere in the Confined Space or High Risk location to be declared safe for entry.

The Responsible Operator issues the necessary “Clearance to Work” with a “Confined Space or High Risk Location Entry Permit” after all hazards associated with entry (if relevant ) are made safe i.e. engulfment, drowning asphyxiation etc. and that an emergency rescue plan is in place.

1

2

3

4

5

6

The ROH or other person designated to measure and asses atmosphere exposure levels may declare the atmosphere in the Confined Space or High Risk Location “Unsafe” at any time, present this written declaration to the Responsible Operator and request that the Responsible Operator orders immediate evacuation.

The Responsible Operator cancels the Clearance to Work in accordance with the Isolation, Lock Out and Clearance to Work Code.

7

A record of each “ATMOSPHERE SAFE FOR ENTRY” and/or “ATMOSPHERE UNSAFE FOR ENTRY” declaration is retained for Record purposes – each “Declaration” should have the unique Works Order number on the form.

8The “Atmosphere Safe for Entry” declaration is cancelled and withdrawn after the work has been completed by the ROH or other person person designated to measure and asses atmosphere exposure levels in consultation with the Responsible Operator.

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10

NoiseInadequate and/or unsuitable Lighting

Moving/loose Equipment

Auxiliary Equipment

Working at Heights

Water / LiquidSlurry

Oxygen DeficientAtmosphere

Harmful Substances

Substances and/or Work resulting in Fires/Explosions

Temperature Extremes

Materials causingengulfment

Additional Hazards (Where Identified)

Hazards to be Considered:

Entrapment


LocationNEVER ENTER A CONFINED SPACE OR

HIGH RISK LOCATION UNLESS:

The responsible Occupational

Hygienist has declared the atmosphere

therein safe for entry.

A HIRA has been carried out for the

work inside the Confined Space or High

Risk Location.

Confined Space / High Risk Location Hazard Guideline

Possible Hazard

Associated Risk/s

1. Noise.

(See Section 9.6.1)

Permanent Hearing Loss Yes No

Loss of Communication Yes No

2. Inadequate and/or unsuitable

lighting.

(See Section 9.6.2)

Injury resulting from unclear vision in the

Confined Space or High Risk Location. Yes No

3. Moving Equipment/Inadvertent

starting of equipment

(See Section 9.6.3)

Injury resulting from contact with moving

equipment in the Confined Space or High

Risk Location.

Yes No

4. Inadvertent starting of auxiliary

equipment external to the confined

space or high risk location i.e. fan,

pump, fuel injectors etc.

(See Section 9.6.4)

Injury dependent on nature of equipment

started i.e. gassing, dust exposure,

drowning, drawn into outlet duct etc.

Yes No

5. Working at Heights.

(See Section 9.6.5)

Injury resulting from falling / falling objects

in the Confined Space or High Risk

Location.

Yes No

6. Water, Liquid or Slurry

(See Section 9.6.6)

Drowning in the Confined Space or High

Risk Location. Yes No

7. Oxygen Deficient atmosphere

(See Section 9.6.7)

Asphyxiation in the Confined Space or High

Risk Location. Yes No

8 Hazardous / Harmful Substances

(See Section 9.6.8)

Injury resulting from contact with, ingestion

or ingress of a hazardous / harmful

substance through a person’s mouth, nose,

eyes, ears and/or skin.

Yes No

9. Substances (including oxygen) and/or

work that could result in fire and/or

explosion.

(See Section 9.6.9)

Burn injuries. Yes No

10. Temperature Extremes

(See Section 9.6.10)

(i) Thermal stress injury resulting from

excessively hot temperatures. Yes No

(ii) Thermal stress injury resulting from

excessively cold temperatures. Yes No

11. Solid, particulate, fluidised and/or

material contained in slurry.

(See Section 9.6.11)

(i) Injury resulting from engulfment.

Yes No

(ii) Injury from falling objects.

Yes No

12. Entrapment

(See Section 9.6.12) Injury resulting from entrapment. Yes No

13. Other/Additional Hazards identified

by team about to enter the Confined

Space or High Risk Location

Risk/s dependent on hazards Identified. Yes No


LocationYou know the precautions to be taken

to protect your safety and the safety of

your team members when you enter the

location.

You have been issued with a Confined

Space or high Risk Location Entry

Permit by the Responsible Operator.

ISOLATION & LOCKOUT

& CONFINED SPACE

Review the Practical Assessment Document

Theoretical training not over due.

Works order or SOP available for task at hand.

Pre work HIRA for task as per Work Order or

SOP done and available.

Can Candidate follow the Isolation and Lock out

steps as per procedure that is reflected in the

Practical Evaluation Sheet?

ISOLATION & LOCKOUT

& CONFINED SPACE

SECTION 2

Confined Space or High Risk

Location Register

• An up to date (risk based) register must

be kept of each area that requires access

control as per the AFRS Equipment

Safeguarding requirements and the

method by which access control achieved• Electronic sensing & recording of permitted entry

• Entry permit

• Locked gate or door with log book records of entry and purpose

• Signage & demarcation with administrative monitoring of

access


Location Register

• An indexed register of each Confined Space or

High Risk Location that requires atmospheric

testing and/or surface temperature before entry

and monitoring after entry must be compiled

and kept in a secure place approved for this

purpose by the Responsible Occupational

Hygienist


Location Register

• Following any atmospheric testing/monitoring in

a confined space or High Risk Location the

Responsible Occupational Hygienist or other

person to whom this function is designated

must ensure that an accurate record of the

atmospheric and/or surface temperature

testing/monitoring and the results thereof are

filed


Location Register

• As far as reasonably practicable, Confined

Space or High Risk Location atmospheric

and/or surface temperature tests/monitoring

must be given the same works order number

that necessitates entry into a particular

Confined Space or High Risk Location to

simplify tracking processes when required


Location Register

• As far as reasonably practicable, Confined

Space or High Risk Location atmospheric

and/or surface temperature tests/monitoring

must be given the same works order number

that necessitates entry into a particular

Confined Space or High Risk Location to

simplify tracking processes when required

• The Responsible Occupational Hygienist must

audit register and records for correctness at

least once a month


Location Register

• A full register/file of the confined space or high

risk locations that require atmospheric testing

before entry and monitoring after entry must be

placed in secure storage and the records

therein must be kept for 5 years; in which case,

a new register must be established

Risk Based exposure levels presented

by the Atmosphere in Confined Space or

High Risk Location• The Responsible Occupational Hygienist, in

consultation with the Responsible Engineer and

SHE Manager, must carry out an assessment

to determine which Confined Space or High

Risk Location have atmospheres that must be

declared safe for entry before a Confined

Space or High Risk Location Entry Permit is

granted by the Responsible Operator for

persons to enter therein

• Where IDLH means:

The concentration that poses an Immediately

Dangerous to Life or Health

• STEL means:

The maximum concentration of a chemical to which

workers may be exposed continuously for up to 15

minutes without danger to Health or work efficiently ad

Safely

• TWA means:

The 8 hour time weighted average exposure to a

contaminant to which workers may be exposed

without adverse effect.

• LEL means:

Lower Explosive Limit

• In addition to any additional atmospheric

exposure tests that may be called for by

the Responsible Occupational Hygienist,

each Confined Space or High Risk

Location must be assessed for the

following known exposure hazards and

where applicable, tests must be carried

out to determine whether any persons

about to enter a Confined Space or High

Risk Location will be exposed to such

hazards:

• Excessively High Temperature and/or

Humidity. Not to exceed 37 ۫ C dry bulb

temperature or 32.5 ˚C wet bulb

temperature.

• Low Temperature not to fall below 6˚C

with appropriate PPE.

• CO gas concentration

Not to exceed IDLH of 1200ppm : STEL of

100ppm or TWA of 30ppm

• CO2 gas concentration

Not to exceed IDLH of 4000ppm; STEL of


• Combustible gases (LEL) Not to exceed

10% of LEL by volume.

• SO2 gas concentration

Not to exceed IDLH of 100ppm ; STEL of

5ppm or TWA of 2ppm

• 02 concentration Max. not to exceed 23%

by volume.

Min. not to fall below 20% by volume

(OHSA requirement should not be

exceeded)

• H2 gas concentration Not to exceed 1.4%

by volume

• H2S gas concentration



• NO gas concentrations



• NO2 gas concentrations


5ppm or TWA of 3ppm

Declaring the Atmosphere in a Confined Space or

High Risk Location likely to present a harmful

exposure Safe for Entry

• Before any person enters any Confined Space

or High Risk Location likely to contain

temperature extremes, noxious, inflammable

fumes or gasses, an atmosphere deficient or

enriched in oxygen and/or a combustible

atmosphere: the atmosphere within such a

confined space or high risk location must be

examined and declared safe for entry by the

Responsible Occupational Hygienist or another

person to whom the responsibility has been

designated in writing

Declaring the Atmosphere in a Confined Space or

High Risk Location likely to present a harmful

exposure Safe for Entry

REMEMBER:

THE “ATMOSPHERE AND SURFACE

TEMPERATURE SAFE ENTRY

DECLARATION FORM” MUST BE

DISPLAYED AT THE ENTRY OF EVERY

CONFINED SPACE OR HIGH RISK

LOCATION WHERE WORK IS BEING

CARRIED OUT

Ventilation and Exposure Monitoring

• Before any of the following work is permitted in

a Confined Space or High Risk Location; the

Responsible Occupational Hygienist in

consultation with the Responsible Engineer,

must determine the measures necessary to

ensure that the Confined Space or High Risk

Location is adequately ventilated and whether

continuous measurements are required for

atmospheric/air exposure levels:


a) Any work requiring a gas source to be isolated in

order to prevent the ingress of a noxious gas, oxygen

replacing gas and/or oxygen into the Confined Space

or High Risk Location.

b) Any work where pipes or other means of

containment of noxious gas, oxygen replacing gas

and/or oxygen are located within the Confined Space

or High Risk Location.

c) Any work that will result in a discharge of a noxious

gas, oxygen replacing gas and/or oxygen within the

Confined Space or High Risk Location


d) Work where the upper or lower ambient

temperature (or other heat source) may cause

temperatures within the Confined Space or

High Risk Location rise above or fall below

prescribed tolerance levels

Remember;

• A risk based survey must be carried out to identify

each Confined Space or High Risk Location in which

the hazards related to (a); (b); (c) and (d) could be

present and any such Confined Space or High Risk

Location must be fitted with appropriate warning signs

at its entrances


• no work may be carried out in any Confined

Space or High Risk Location unless it is

ventilated with a clean/fresh air flow volume that

provides at least 30 air changes per hour

inside the Confined Space or High Risk

Location.

• The ventilation within the Confined Space or

High Risk Location is such that no recirculation

of air takes place anywhere.


• Where a portable fan is used to provide

additional ventilation, the intake or suction of

the portable fan must be located in clean air

and draw clean air in a manner that prevents

hazardous gasses, fumes, dust or vapours from

entering the Confined Space or High Risk

Location.


• As a minimum continuous monitoring

precaution, a reliable and appropriately

calibrated gas monitor, set to alarm before

exposure levels become unsafe, must be left

under the care of a person who understands its

functions and is able to call for evacuation of

the Confined Space or High Risk Location

under such conditions.


• Whenever there is a risk of exposure to atmospheric

hazards inside a Confined Space or High Risk

Location, at least one other person (trained in

appropriate recue and resuscitation requirements) will

remain in attendance immediately outside the

entrance of the Confined Space or High Risk Location

for the duration of the entry in order to assist or call for

assistance with the removal of any person or persons

from the Confined Space or High Risk Location in

case of an emergency and a means of communication

between the inside and the outside of the Confined

Space or High Risk location will be maintained at all

times.


• REMEMBER

A Risk based assessment must be carried out to

establish whether a harness must be worn and

attached to a lifeline of suitable length by persons who

enter therein with its free end being left under the

control of the above person who has been trained in

appropriate rescue and resuscitation requirements

Ventilation Formulae associated with 30

air changes per hour

Formula for determining minimum air flow volume to

achieve 30 air changes per hour; Volume of air required = Volume of ventilation space x required air changes per hour

3600 seconds

Formula for determining the number of air changes for

any given air flow volume;Volume of air changes per hour = Volume of air supplied by fan X 3600 seconds

Volume of space being worked in

Requirements for Atmospheric Testing

and Monitoring

• Atmosphere testing and monitoring in any Confined

Space or High Risk Location must be carried out in

accordance with standard work instructions and

procedures approved by the Responsible

Occupational Hygienist in consultation with the

Responsible Engineer.

• The Responsible Occupational Hygienist must

approve all equipment that is used for atmosphere

exposure testing and monitoring


and Monitoring

• All atmosphere exposure testing and monitoring

instruments used for Confined Space or High Risk

Location measurements must be checked, confirmed

suitable for continued use and calibrated by OEM or a

competent person / service provider designated by the

Responsible Occupational Hygienist in consultation

with the Responsible Engineer on a six monthly basis.

Alarm settings must be specified by Responsible

Occupational Hygienist, recorded and signed as such

in the Register of Confined Spaces and High Risk

Locations that require atmospheric testing before entry

and monitoring after entry.


and Monitoring

• Where atmosphere exposure testing is required before

entry and/or continuous monitoring is required after

entry, the method used for such testing and monitoring

must be approved by the Responsible Occupational

Hygienist.


and Monitoring

• REMEMBER:

1.A record must be made of all instruments issued for

continuous and/or personal monitoring. This record

must be retained by the person authorised to declare

the atmosphere and surface temperatures in the

Confined Space or High Risk Location safe for entry

until the work is complete and forwarded to the

Responsible Occupational Hygiene Technologist for

Record keeping


and Monitoring

• REMEMBER:

2. The person issuing the above instrument must explain

its function and purpose to the person who it is being

issued with.

3. The person issued with the above instrument must not

take charge of it unless he/she understands its

function and purpose.

Requirements for Surface Temperature

Testing and Monitoring

• In addition to carrying out initial testing of surface temperatures

that are within reach in a Confined Space or High Risk Location

in which the risk of burn injuries has been identified, periodic

testing and recording of surface temperatures must be carried

out by a person designated for this purpose by the responsible

Occupational Hygienist at intervals not exceeding 30 minutes

while persons are in Confined Space or High Risk Location.

Should total evacuation of such a Confined Space take place

for any reason whatsoever, the aforementioned person will test

the safety of all surface temperature within reach before re-

entry may be permitted.

Designations and Competency of

Persons authorised to take Atmospheric

Exposure Measurements• Atmospheric Exposure measurements shall only be taken by a

person who is trained, competent and designated by the

Production Manager in consultation with the Responsible

Occupational Hygienist and the Responsible Engineer to carry

out, evaluate such measurements, and determine whether the

atmosphere inside a Confined Space or High Risk Location is

safe for persons to enter and remain safe while persons work

therein.

Record keeping of the “Atmosphere Safe

for Entry” declaration forms

• After the Responsible Operator takes possession of

the cancelled “Atmosphere Safe for Entry” declaration

form he/she will ensure that the document contains

the unique Works Order number before retaining the

document for record purposes

Basic requirements for Occupations that are

permitted to declare the Atmosphere and

Surface Temperatures in a Confined Space or

High Risk location safe for entry

• Occupations;

* Responsible Operator (As defined in the Isolation,

Lock-out and Clearance to Work Code)

* Safety Officers

* Environmental Coordinator

* Occupational Hygienist





• Requirements;

Every Occupation mentioned above must receive

Environmental Conditions Measurement training that

includes Thermal and Gas exposure measurement,

from an approved training facility. The training must

cover all theoretical and practical requirements. The

training must incorporate the use of site specific

monitoring equipment when the training is in progress.





• Requirements;

Every person must receive a certificate from the

training company stating that they have been trained

in measuring Environmental conditions – they must

then be designated to an extent clearly defined in

writing as a (Competent) person who is authorised to

carry out Environmental testing by the Smelter

Manager.





• Instruments;

All gas monitoring instruments used for confined space

or High Risk Location measurements must be

calibrated on a six monthly basis, and all alarms must

be set to established OEL or STEL levels.

Any instrument used to determine the temperature in

the confined space or high risk location must be

calibrated on an annual basis.





• Limitations;

If any instrument raises an alarm while testing a confined space

or high risk location, no entry will be permitted, the

Occupational Hygiene Technologist or Hygienist must be

contacted and made aware of the high levels. The OHT or

Hygienist will then, depending on the measurements and

current conditions, make a decision on what additional control

measures must be put in place for safe entry. After additional

control measures have been recommended the current HIRA

needs to be reviewed.

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