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Report of

Two Days Workshop on Confined Space Safety

(16th – 17th March, 2010)

At Kerala State Productivity Council, Productivity House, HMT Road, Kalamassery, Ernakulam District, Kerala State, India

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Dr. M. Beena, IAS, District Collector, Ernakulam, Inaugurating the two day work shop on ‘Confined Space Safety’ held at Productivity House, Kalamassery on 16th -17th March, 2010 organised by Kerala

State Productivity Council, Kalamassery in association with Disaster Management Institute, Bhopal, InWEnt, Germany & gtz, Germany

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1. Executive Summary CODE: Title : Kalamassery - Confined Space Safety Short title: Kalamassery - Confined Space Safety

Training Type:

Awareness Training on hazard assessment and control procedures before entering a confined space for Engineers, Managers, Executives, Supervisors and workers of any organization exposed to confined space working and also to fire and Municipal services who enter such space for rescue operations.

Thrust Area HRDP: Human Resource Development

Targets: Industries, Administrators, Fire and rescue services, NGO’s, Defense Services, Media, Red Cross

Training provider: Kerala State Productivity Council, Disaster Management Institute, Bhopal, InWEnt, Germany, gtz, Germany

Institutions involved DMI, InWEnt, gtz, Kerala State Productivity Council, Safety Technical Services

Workshop objectives :

A series of the lectures have been organized by distinguished speakers with video clips and video shows. On the second day a practical training is organized at a separate venue in a training Institute with hands- on training with case study on Confined space entry Safety. The objective is to provide information on what is confined space, hazards associated with confined space and assessing hazards, preparation for entering the confined space with various checking, emergency response precautions and Safety precautions, case studies with hands-on training.

Achieved result:

Good feedback from participants. The practical exercise on case study was well appreciated as each one got an opportunity to prepare a permit to work. They also recommended such classes to all Fire and Rescue team and to help them financially to provide equipments required for such rescue operations.

Description of contents/Agenda:

Registration Inauguration and key note address - Dr. M. Beena, IAS,

District Collector, Ernakulam by lighting “Nilavilakku” (lighting traditional lamp)

Presentation on “ An overview of Chemical Disaster Management in India” by Mr. K M Amanulla, Member –core group for Hazard analysis, Ministry of Environment and Forest, Govt.of India) and Programme Director, Health, Safety and Environment cell, Kerala State Productivity Council

What is confined Space? Hazards associated with Confined space and assessing hazards by Dr Rakesh

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Dubey, Director, Disaster Management Institute, Bhopal. Preparations for entering the confined space: Air qualities,

Isolation, Respiration, Fire prevention by Sri K M Kabier, Safety Consultant & Trainer.

Emergency Response and Safety Precautions by Sri C Mahadevan, HSE Consultant &Trainer.

Practical training on “confined vessel entry” at Safety Technical Services Co.Ltd, Kanjoor, Kerala

Capacity building of the participants by objective Test, Feedback, Valedictory session and giving away of certificates.

Number of participants: 60

Start: dd/mm/yy : 16th March 2010

End dd/mm/yy : 17th March 2010

Duration: 2 Days

Venue:

Productivity House Auditorium, Productivity House, Kerala State Productivity Council, HMT Road, Kalamassery, Ernakulam District, Kerala State, India. Pin- 683104

Contact for more information : Mr K M Amanulla at Producivity House, Dr. Rakesh Dubey DMI, (Bhopal)

Resource persons//Trainers: Dr.Rakesh Dubey DMI, (Bhopal), Shri K M Amanulla,(Co-ordinator), Shri K M Kabier(Speaker), C Mahadevan (Speaker) and Case study co-ordinator

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1.0 Background Disaster Management Institute (DMI), Bhopal, in association with Kerala State Productivity Council, Kalamassery, Ernakulam District, Kerala State, organized a two days training cum-awareness programme with the support of InWEnt and GTZ, Germany under the Indo-German bilateral cooperation on “Confined Space Safety” with the objective of imparting safety awareness in the area of Confined Space entry. (Ref. Annexure I for Programme Brochure) The prime objectives of conducting the programme are to: * recognize and control the hazards associated with confined space management in Industries,

Fire and Rescue services, Media, Administrators * To provide an opportunity for practical training with hands-on training on confined space entry

permit preparation and working inside a confined space with required equipment and their use by practical demonstration.

Under the Indo-German bilateral programme, in addition to organise the number of training programmes, a web platform www.hrdp-idrm.in has also been developed to achieve all training related activities. The details of the programme and activities have been made available at web platform on www.hrdp-idrm.in for view and download of the relevant information. 2.0 The need of the programme In the area of Confined Space Safety programme, under the DMI, Bhopal and Indo-German bilateral programme, the need for transfer of knowledge, demonstration of state-of-the-art technologies and procedures that can create multiple effects in the area of Confined Space Safety was expressed with organization of a series of the awareness and training programmes. To make it more effective, a series training / awareness at the regional level with various stakeholders have been planned. The programme at Kalamassery, Cochin, is planned to cater India’s southern most, industrialized and high literacy state of Kerala with the following thrust: * To recognize and control the hazards associated with confined space management in Industries,

Fire and Rescue Services, Media, Administrators * To provide an opportunity for practical training with hands-on training on confined space entry

permit preparation and working inside a confined space with required equipment, their use by demonstration.

* To discuss about the possibilities for a joint use of www.hrdp-idrm.in web platform for knowledge management and management of training events

3.0 Overall objectives The overall objectives of the workshop is to impart awareness and knowledge in the area of confined space entry safety with precautions in preparing permit to work. Awareness: To provide awareness on the following:

What is a confined space? What are the hazards in a confined space Preparations for entering the confined space, safety precautions

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Emergency response precautions Entry permit system Practical training with preparation of a confined space permit to work after seeing the

confined space, issue, receive permit, carry out a specified job with hands-on training on the equipment/instruments required for this.,

4.0 Programme details Dates and Venue: The programme commenced on Tuesday, 16th March, 2010 and concluded on Wednesday, 17th March, 2010 successfully at Productivity House auditorium, Kalamassery, Cochin, Kerala State. Registration The programme started as per schedule on Tuesday, 16th March, 2010 with the registration of the participants. The participants assembled in the Reception Counter for registration at 9.30 am Inauguration Shri. K.V Ramachandran, Vice Chairman, Kerala State Productivity Council, welcomed the dignitaries, the participants from various fields, Media persons and others Shri Mr. K M Amanulla, Member –core group for Hazard analysis, Ministry of Environment and Forest, Govt.of India) and Programme Director, Health, Safety and Environment cell, Kerala State Productivity Council, highlighted that a number of workers are injured or killed every year while working in confined spaces. An estimated 60% of the fatalities each year have been among the would-be rescuers, hence the importance of training on such a new subject and its practical training. This is the first time such training is being conducted. Dr Rakesh Dubey, Director, Disaster Management Institute, highlighted the activities of DMI in various states of the country and the Formation of Disaster Management Act in 2005. He also explained the formation of Chemical Wing of DMI and the Guidelines formed in Bhopal in 2006. He added that 15 more programs to be held across India on Confined space safety with the purpose of educating and creating awareness for various personnel and Preparedness for various disasters. He appreciated the efforts Kerala State Productivity Council, Kalamassery for initiating to organize such training. Dr. M Beena, IAS, District Collector, Ernakulam inaugurated the programme by lighting “Nilavilakku” at 10.00 am. In the inaugural speech, the collector recollected the Impact of Tsunami hit on the coastal area of Kerala state and the necessity for Disaster Management. The collector expressed concerns about the recent LPG tanker fire incident at Karunagapilly in the Kollam district, Kerala where rescuers become the causalities. The collector urged the participants to be well prepared & equipped to face any disaster as they are directly involved. Accidents are happening in industries arising from the poor awareness and inadequate knowledge of employees. The collector appreciated the efforts of Kerala State Productivity Council and Disaster Management institute, Bhopal for arranging such an important and timely relevant programme on confined space safety. Dr. V.Muraleedharan Nair, Managing Director, Travancore Cochin Chemicals Limited highlighted the importance of safety in production areas. He urged all participants to follow safety measures by making safety as day to day activities to avoid accidents.

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Dr G Madhu, Professor & Head, Safety and Fire Engineering Department, Cochin University of Science and Technology, Cochin. In his felicitation address, explained the definition of confined space and the practicality of ‘safety & Emergency preparedness before entering in to confined space. Shri E V Prasad, Divisional Officer, Fire & Rescue Services, Cochin, highlighted that the subject of Confined Space Safety is very much relevant to their day to day activities. He expressed his happiness to see that his people could participate in the training. He requested DMI and KSPC to conduct more such programmes. Shri.G. Sivakumar, Director, KSPC gave vote of thanks to all the dignitaries, participants and others who attended the inaugural function making it a memorable one. The local news papers, Malayala Manorama and Madhyamam daily widely covered the inaugural function of the programme on ‘Confined Space safety’ on the 17th March issues. Attached herewith as Annexure II. After the inauguration, the programme was started as per the schedule given in Annexure III. The session by activities is listed below: Session 1: Shri K.M Amanulla started the session and gave a presentation on ‘An overview of Chemical Disaster Management in India’ Session 2: Dr Rakesh Dubey started the second session and delivered talk on “What is confined space? Hazards associated with Confined Space and assessing hazards. He highlighted the different types of confined space, what are hazards and risk, how to identify hazards and assess risk in a confined space. He also highlighted the requirement of various safety precautions to be taken before entering a confined space Session 3: Shri K M Kabier explained in detail about confined space and related topics like air quality, what isolations need to be done and how, what are different types of hazards inside a confined space, how to check them and eliminate them, what are the chances of a fire in a confined space and what precautions need to be taken. Two videos on Confined space entry were played. He also explained on risk assessment before going inside a confined space. Session 4: The second day, Shri C Mahadevan explained the meaning of entry with respect to confined space including insertion of head. He highlighted some important precautions to be taken before/while entering a confined space including the Emergency preparations. He explained the statutory regulations related to confined space as per the Factories Act and Kerala Factory Rules. Lot of case studies were discussed with participants. Video on hazards of nitrogen asphyxiation, on total safety related to confined space s shown. Video on recent LPG Truck fire incident occurred at Karunagapallly in Kerala state, was shown to explain how rescue persons can get killed if precautions are not taken by all concerned. Session 5: For the next session, the participants were taken to a Training Institute namely Safety Technical Services Co Ltd, Kanjoor, Ernakulam Dt. for practical training on confined vessel safety. Shri C Mahadevan explained the participants about a syndicate exercises dividing the total participants in two A and B groups. C Mahadevan and others were observing the participants and their actions. Both the groups discussed all safety aspects and he appreciated their efforts in finding out hazards, analyzing them and writing/following precautions.

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Shri Viswanathan Nair and Shri Oomen, Faculties , Safety Technical Services Ltd explained various aspects of wearing PPE. Demonstration was given on using/wearing various equipment like oxygen meter, explosive / toxic gas analyzer (H2S, CO), SCBA, ELSA escape apparatus, life line, safety belt and many other PPE. Session 6: Sri Viswanathan Nair and Sri Oomen explained about the types of fire and demonstrated an oil fire and how to use CO2 and DCP extinguishers. How to use a self contained breathing apparatus was also shown by wearing it. Participants were also shown and explained the various types of rescue, fire fighting including self contained breathing apparatus and other equipments being used for training. . Programme evaluation sheets were distributed to the participants by Dr Neeraj Khera and received the same from them. Session 7: Next session was a test for the participants.15 objective questions were given to each of them and asked to tick mark correct answer out of three answers given. ( Ref.Annexure 8, test paper questions) After completion the answer papers were shuffled and given to them. Shri. C Mahadevan gave the correct answer and the participants valuated the papers. 7 participants got 100% marks. All of them got above 75% marks showing that the participants learned relevant information from the training and the training was successful. Session 8: In the feedback session, Shri Sivakumar, Director, KSPC asked the participants to tell about the programme. Four participants expressed their opinion about the programme. The feed back was good. ( Ref Annexure 8) Session 9: Certificates were issued to all participants who successfully completed the two days training programme. Certificates were distributed by Dr Neeraj Khera. Session 10: A valedictory programme was organized for concluding the programme. Dr Rakesh Dubey expressed his happiness on the feed back and promised that he will arrange more programmes with KSPC. Sri C Mahadevan thanked the participants for actively participating in the syndicate exercise and practical training and the permit issue and acceptance has covered almost all precautions for the given job. He also thanked them for scoring good marks in the test. Test papers were given back to participants after evaluation. The profile of faculties/lectures are given in Annexure - IV 5.0 Participants Altogether 60 participants as per the Annexure V, participated in the programme. Most of the participants are responsible for issuing permits in their respective areas. Former Director of Factories & Boilers, Shri V.J Francis Xavier , Sri Narayana Pillai, Former General Manager of FEDO (FACT unit ), Shri. A.K Nair, Vice Chairman, SCMS group of institutions, Shri K.M.George, Sigma Management Services also attended the programme. Short description about participating Institutions is given in following paragraphs:

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Disaster Management Institute (DMI) DMI was established in 1987 in the backdrop of world’s worst ever chemical disaster in Bhopal. The President of the organization is the Chief Minister of MP and the vice President the Minister of Environment of the state. The principal objective of the institute is to evolve the techniques for and enhance competence in prevention, mitigation and management of natural as well as industrial disasters in India. The other objectives includes – - Train government officials, executives of PSUs and private sector firms in various facets of

Disaster Management. - Carry out research on causes, effects etc. of disasters. - Collect, store and effectively disseminate information regarding hazards and Disasters for

mitigation and prevention state-of-the-art techniques. - Offer consultancy services to the industries and others. - Institute awards, medals, scholarships and prizes to promote these objectives. - Presently the institute is partner with InWEnt-GTZ-ASEM on capacity development project on

iDRM under Indo-German bilateral programme. Institute is also working very closely with MOEF, GOI and NDMA to develop national policies and programmes on disaster management and coordinates with various state governments.

Kerala State Productivity Council (KSPC)

The Kerala State Productivity Council was established in 1959 as an autonomous tripartite organization with representation from Government, Management and Labour. The Council is affiliated to the National Productivity Council, New Delhi and Asian Productivity Organization, Tokyo, Japan.

The basic mission of KSPC is to enhance productivity, through its promotion activities, in all walks of human endeavor. It considers productivity as a grass-root, level movement essential to nation building. The Council is now one of the premier productivity organizations in the country for imparting Training in Productivity Techniques and providing Consultancy Services

KSPC which has become ingrained in the industrial scene in the state of Kerala, had conducted studies in most of the medium and large scale organizations and provided consultancy services for all-round Productivity improvement. KSPC is spearheading the Productivity movement in this State, especially in the present competitive environment. KSPC had been adjudged as the best local Productivity Council in India by NPC and in the past 48 years of its existence the Council has emerged as one of the best and leading Productivity Councils in the country.

Objectives of KSPC. • To increase productivity in all fields of human endeavor. • To stimulate and promote Productivity consciousness in the minds of the people. • To encourage and assist in implementation programmes relating to the objective of increasing

Productivity. • To seek and to promote the establishment of cordial relationship between employers and

employees, and, • To provide Advisory Services for industries to facilitate introduction of Productivity Techniques.

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Safety Technical Services Pvt. Ltd Safety Technical Services Pvt. Ltd provided the practical training. This institute was formed with the merger of Safety Marine Services, United Arab Emirates & Safety Audit services, United Kingdom in 1993. They manufacture, supply, test, and certify lifting tackles and rigging equipment, wire ropes, slings and accessories, thread testing and HSE services. For further details contact Tranquil Towers, Near Civil station, Seaport-Air port road, Kakkanad, Kochi, 30 Major Accidents Hazards (MAH) industries The following categories of industries were present across the whole state of Kerala:

o Chemical fertilisers, o Chlor-alkalies, o Metallurgical, o Heavy Engineering, o LPG, o Refineries, o Fine chemicals o Insecticides o Rubber Chemicals o Etc.

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6.0 Conclusions and Recommendations The second day concluded with valedictory session with the following recommendations:

1 More such training must be conducted and DMI should extend all help. 2 Fire and rescue services requested to conduct more such programmes covering all their

officers. 3 From the participants feedback, the two days training was very useful. They said they will try

their best to implement the actions. They thanked the representatives from DMI & KSPC for extending all the help in conducting this programme. They requested DMI & KSPC to continue such programmes in future also

4 Most of the participants admitted that they have the basics but tend to forget things in practice and this was good refresher training. People have the tendency not to follow systems after practicing for few years. So this course has been useful.

5 Sri C Mahadevan informed that the syndicate exercises (Annexure – VI) were well discussed by all participants before finalizing the Confined vessel entry permit to work. He congratulated the participants for a successful exercise.

6 Course Validation question paper was given to all participants. They answered them. Correct answer was read out and about 35% participants got 100% marks, confirming that the participants got correct and good information (See Annexure – VII for the Questionnaires).

7 Certificates were issued to all participants by Dr Neeraj Kheera, Programme Coordinator, inWEnt Regional Office New Delhi. Dr Rakesh Dubey , Director, DMI, Bhopal, in his concluding speech, expressed his happiness on the feedback from the two days training course and assured that more such courses will be conducted.

8 The course concluded at 4 10 pm.

Consolidated Summary of Evaluation of the Workshop is attached as Annexure VIII. Verbal feed back summary is attached as Annexure XI.

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Annexure-I Two-Day Workshop on

Confined Space Safety (On 16th & 17th March, 2010 at Productivity House, Kalamassery)

Kerala State Productivity Council in association with Disaster Management Institute, Bhopal, GTZ ASEM and InWEnt Germany is organizing a two day Workshop on Confined Space Safety. A number of workers are injured or killed each year while working in confined spaces. An estimated 60% of the fatalities each year have been among the would-be rescuers. The fatalities typically occur for two reasons:

1. Employers and workers fail to recognize and control the hazards associated with confined spaces, and

2. Inadequate or incorrect emergency response results in the death of the initial entrant, the would-

be rescuer, or both To effectively control the risks associated with working in a confined spaces, a Hazard Assessment and Control procedures should be implemented for your workplace. The two day workshop will give participants / employees an opportunity to understand and practice Confined Space Entry procedures to be implemented at the workplace. PROGRAMME COVERAGE

• What is a confined space? • Hazards in a confined space • Preparations for entering the confined space • Emergency response precautions • Other safety precautions • Entry Permit System • Practical training

FACULTY The core team of trainers for this two day workshop will be led by Dr. Rakesh Dubey, Director, Disaster Management Institute, Bhopal. PARTICIPANTS

Engineers, Managers, Executives, Supervisors and workers of any organization exposed to confined space working.

DATE, TIMING AND VENUE

16th and 17th March, 2010 from 9.30 a.m. to 4.30 p.m. at Productivity House, Kalamassery

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FEE The fee per Participant will be Rs. 2500/- + Service Tax @ 10.3% Delegate fee may be made in the form of Cheque / DD in favour of KERALA STATE PRODUCTIVITY COUNCIL. GENERAL

Well prepared course material by DMI & GTZ Germany, folder, writing, pad, pen etc. will be supplied.

Lunch and refreshments will be served. There will be arrangements for practical training at separate venue. Transport arrangements will

be provided for the same REGISTRATION Organizations, which intend to send participants, may kindly intimate us the name of the participants by mail. Nominations can also be made through Phone: 0484 - 2555526/2555367, Fax: 0484 - 2532107 Mobile: 98470 – 15362 or e-mail: kspc@asianetindia.com Last date of receiving nomination is 12th March, 2010.

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Annexure – II

Madhyamam Daily

Malayala Manorama Daily

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Annexure – III

KERALA STATE PRODUCTIVITY COUNCIL, KALAMASSERY - 683 104

Two-Day Workshop on ‘CONFINED SPACE SAFETY’ Organised in association with

Disaster Management Institute, Bhopal, gtz, Germany and inwent, Germany at Productivity House, HMT Road, Kalamassery

PROGRAMME SCHEDULE

16.03.2010 (FIRST DAY) 09.30 AM – 10.30 AM : Inauguration 10.30 AM – 11.00 PM : An overview of Chemical Disaster Management in India

(Mr.K.M Amanulla, Member-Core group for Hazard Analysis, Ministry of Environment & Forests, Govt. of India)

11.15 AM – 12.30 PM : What is Confined Space? Hazards associated with Confined space and

assessing hazards (Dr Rakesh Dubey, Director, Disaster Management Institute, Bhopal)

01.30 PM – 03.00 PM : Preparations for entering the confined space - Air qualities - Isolation - Respiration - Fire prevention (Shri K.M. Kabier, Safety Consultant & Trainer) 03.30 PM – 04.30 PM : Preparations for entering the confined space 17.03.2010 (SECOND DAY) 09.30 AM – 11.00 AM : Emergency Response Precautions - Emergency Response - Safety Precautions Entry permit system (Shri C. Mahadevan, Safety Consultant & Trainer) 11.15 AM – 03.00 PM : Practical Training at Safety Technical Services Co. Ltd. Kanjoor 04.00 PM – 05.00 PM : Valedictory session at Productivity House, Kalamassery 11.00 AM– 11.15 AM & 03.00 PM – 03.15 PM : Tea break 12.30 PM – 01.30 PM : Lunch Break

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Annexure – IV Profile of Faculties/Lectures

Sri Amanulla K.M

K.M Amanulla, Graduated in Mechanical Engineering from Kerala university, 1967. Work experience for a total of 30 years in Department of Factories and Boilers out of which 4 years as the Head of Department. He was a member of the Kerala State Pollution Control Board and also Former Chairman of National Safety Council, Kerala Chapter and Kerala State Productivity Council. He is Instrumental in preparing the Off-site Emergency plan for Ernakulam District and the local plan for Karunagappally Taluk. Presently member of the Co-group for hazard analysis constituted by the Ministry of environment and forest, Govt. of India & Programme Director, Health, Safety and Environment cell, Kerala State Productivity Council,

Sri K M Kabier K.M Kabier, Graduated in Chemical Engineering from Trichur Engineering College, Calicut University. Work experience of total 23 years in Kochi Refineries Limited and Abu Dhabi National Oil Company (ADNOC). He Worked with Shell Global for the Safety Integrity Level (SIL) and Risk Based Inspection (RBI) studies. Also worked with DNV Middle East for the implementation of HSE Management System in the Refinery. He has Conducted HSE Management System Audits. Presently working as HSE Trainer.

Sri C Mahadevan C Mahadevan is a postgraduate in Pure Chemistry from Kerala University with first rank in B.Sc chemistry and fourth rank in M.Sc chemistry. He was working with ICI India Limited, a U K based Multi national chemical company for 36 years in different capacities as Quality Assurance Manager, Plant Manager for urea packing, R&D Manager, Plant & Production Manager for Resins and Paints plant and for 12 years as Head of Security, Safety, Health, Hygiene and Environment Department of the same company in their Paints and Rubber chemicals units. He has undergone special HSE and Occupational Hygiene training in ICI UK. He is an accredited ISO Lead auditor under BVQI. He has conducted many HSE audits in Kerala and India. He organised many seminars and took active part in various seminars and workshops organised by West Bengal Directorate of Factories, Pollution control board, Indian Chemical Manufacturers association, Bengal Chamber of Commerce and Industries and Indian Management Association. He was in the committee /team for tackling an Off-site emergency in the Customs go down fire incident near Das Nagar in west Bengal for which he got appreciation from the Government of West Bengal. He has also been trained in HAZOP studies in ICI and conducted various HAZOP studies for Industries. He has been a visiting faculty for various Industrial institutes in West Bengal conducting Diploma in Industrial safety including Regional Labour Institute, Calcutta and also was examiner, preparing question papers and evaluating the same for two years. He was an Executive Committee member of National Safety Council, West Bengal Chapter for 8 years. He is a life member of National Safety Council. Since retirement in 2001, he has been closely associated with National Safety Council, Kerala chapter as their regular faculty for various HSE training, HSE audits in Industries in Kerala and outside, for preparing on-site emergency plans and conducting mock drills in industries. He has been a faculty for Domestic/Home and Road safety. He helped Directorate of Factories to put the initial off-site emergency plan of Ernakulam District in computer and was in the committee. He has also been the main faculty for the “Safety in transportation of hazardous chemicals by road” training conducted for Police officers by National Safety Council, Kerala State Productivity council jointly with Ministry of environment and Forest. More than 30 training classes

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were conducted covering about 1200 police officers. He is also a faculty for institute of Land and Disaster Management, Thiruvananthapuram. He presented various suggestions to a high level committee representing chief secretary ,DGP and Revenue Minister of Kerala Government for preventing hazardous chemical tanker accidents and their mitigation. He is the author of the booklet published for Police training and also various other Safety related manuals for Industries.

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`Annexure - V

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Annexure-VI Syndicate exercise and Permit to work format Syndicate Exercise on Confined Vessel Entry permit with practical training Divide the participants in to two equal groups, Group A and Group B Both groups will select a leader. Group A will prepare the permit to work clearance for doing the job given below after discussion and hand over the permit to Group B leader. Group B will discuss the important points once they get the work permit for confined vessel entry and carry out the work. Once the job is completed, leader of each group will present the important points/observations followed by discussion. Work to be done: A Prepare a Permit to work clearance in the form given below to

1 clean the inside of a furnace(gas) chamber used for burning LPG gas with air to oxidize the product to next stage.

2 To attend to the damaged side wall of the inside of the chamber involving welding job.

And carry out the job. Permit to work blank form is given. Typical Confined Space or Confined Vessel entry permit clearance certificate format: ( This certificate is valid only till the end of general shift or 5 pm of the date f issue. For any emergency work after 5 pm, the permit must be renewed duly authorized and signed by Authorized person/ HOD. ) Plant area: Sr No of the closed vessel entry permit----------------------- Section of the Plant: Name of the confined Vessel/equipment / equipment number: Area/Parts/Location Details of the jobs to be done: II Details of the hazard identified: Precautions 1 Source of entry of steam or other non-toxic gases, fumes, liquids etc Isolated by stopper or slip

plate/blank / disconnection of line. 2 Source of entry of toxic gases, fumes and liquids Isolated by physical

disconnection of lines or slip plate/blanks. Number

of the plates: Possibility of emission of toxic/lethal gases, fumes & liquids Standby person outside the from outside area. Vessel to raise Alarm during

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emergency 4 Source of energy, power, where it is operated or contains Electrical isolation power operated machinery. necessary…..Yes/No If yes, isolated by which

method? Isolated by electrician Signed by………………….Date…..Time Electrical Supt/Nominee 5 Sludge /deposit contamination inside 1 Cleaned. 2 Not cleaned/Deactivated Use PPE as given below /SCBA required ? 6 Ventilation 1 All mountings are open 2 Continuous air purging kept on. 7 In case of welding to be done inside 1 MSA/Flammability test to be done.

Result……….Below 10% LEL. Tested by…………Signature…… Date…../Time………. Other safety precautions: 1 One man to be kept standby outside vessel Yes 2 Personal Protective Equipment to be used. Tick off those required 3 Additional permit like Hot work permit required? Yes/No 4 Atmosphere in confined vessel to be tested for Yes oxygen using oxygen meter I certify that I have tested the atmosphere in the above vessel/confined space on date……….. at……… hrs and found that it is free from hazardous fumes, gases & liquids. Percentage of oxygen inside the vessel is …………..% (general acceptable limit is 20.0-20.6%) Signed Date Time Laboratory/Safety person

I certify that men can work safely inside the vessel till he starts feeling uncomfortable with precautions mentioned above.(normally 10 minutes. Change person after 10 minutes)

Signed Process Supt Date/Time

I have examined the precautions stated above and confirm that the confined space / vessel is safe for working inside.

Signed Plant Manager/ Production Manager Date//time (Authorized person as per Factories Rules)

Safety Precautions as stated above are understood and accepted.

Signed Engineer/ Maintenance supervisor Date/Time

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After completion of the job: Job has been completed satisfactorily by maintenance Signed by Engineer/ Maintenance Supervisor Date/Time Requested electrical dept for power supply Power supply given at……… Signed by electrician Date/Time Trial run ok Vessel/ equipment accepted after the job and is satisfactory. Signed by process Supt Date/Time Tick PPE required:

Helmet / Goggles / Face shield / Nose protection/ Respirator/ SCBA / Gloves/ Safety belt/ Life line/ Any other-specify

Note: Only 24 V hand lamp which is properly sealed is permitted inside a vessel for use. The hand lamp should have a continuous cable without any joint. The bulb must have a guard to prevent any breakage. If work is to be continued after 5 pm, the permit must be renewed checking oxygen again and with permission and signatures of all concerned including the authorized Plant Manager

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Annexure - VII Training Validation Confined Vessel Entry Permit: Training evaluation Questionnaires: Tick true or false 1 Issue of confined vessel permit is the responsibility of the owner True / False of the equipment. 2 For digging a 7 feet deep pit and for going inside, confined vessel True / False permit is not required. 3 No closed vessel entry permit is required for a contractor’s man True / False going inside an empty water tank for inspection. 4 Only responsible managers can authorize issue of confined True / False vessel entry permit with his signature as per Factory Rules. 5 A confined vessel entry permit is not valid for more than 8 hours. True / False 6 Before doing a welding job in a confined vessel, the flammable gas True / False test result result must be below 10% of LEL. 7 Ordinary flood light can be used inside confined vessel for lighting. True / False 8 Slip plate or blinds have to be put only in liquid pipe lines, not True / False required to be put on gas pipe lines. 9 If the Confined vessel job is not completed in one day, same permit True / False can be used next day also with out any further tests/renewal. 10The 24 v light used inside the vessel must have continuous cable True/ False without any joint and the bulb must have a proper guard. 11 The blanking plate or slip plates fitted for isolation need to have True/ False numbers in each for identification and these numbers must be written in the permit. 12 Work can be done inside a confined vessel if Oxygen content True / False is15-16%. 13 If the confined vessel is containing flammable vapor,it can be cleared True/ False by purging with nitrogen and people can enter the confined vessel immediately after such nitrogen purging. 14 In case the person who went inside a confined vessel becomes True / False un-conscious, the standby person must immediately rush inside and rescue him without waiting to wear required PPE. 15 The integrity of electrical isolation must be tested by actually True / False operating the switch of the drive before vessel entry.

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Annexure-VIII

Consolidated Summary Sheet for Participant - Evaluation of the Training Course

Programme / Course / Workshop Title Two day workshop on Confined Space safetyCode enter training event codeTraining Institution Kerala State Productivity Council,DMI, InWent,GTZDuration from 16/3/2010 to17/03/2010

Overall training course and objectives (Q: 9-1, 6-1 to 6-3 and 5-1 to 5-3)Number of questions (7) Evaluation Rating** where response rounded average is equal to Index (EI)*

1 2 3 4 5 2 5 0 0 0 5.75 very successful

Objectives: 6-1-1 To assess hazards associated with confined space entry

6-1-2 To understand control procedures to be implemented at work place regarding confined space entry

6-1-3 To provide practical training on hazard control and mananegemnt

Organisation and venue (Q: 7-1 to 7-11) Number of questions (11) Evaluation Rating** where response rounded average is equal to Index (EI)*

1 2 3 4 5 0 9 2 0 0 7.75 very good

Methodology / learning effect - How do you assess (Q: 4-1 to 4-5 and 3-1 to 3-5) Number of questions (11) Evaluation Rating** where response rounded average is equal to Index (EI)*

1 2 3 4 5 1 10 0 0 0 8.5 very good

Remarks Relevance and impact of the work (Q: 2-1 to 2-4) Number of questions (4) Evaluation Rating** where response rounded average is equal to Index (EI)*

1 2 3 4 5 2 2 0 0 0 3.5 very good

Based on the rounded average of all modules Questions 3.6 and 3.7The complexity of the course / module content was just right The amount of information was just right

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Annexure-XI Verbal Feed back from the participants from two days training on Confined Vessel entry safety: 1 Ashim, HOC: The two days training was very informative. I have joined the company recently and as a beginner and working in a chemical plant I got lot of information from the training. The safety norms are stringent outside world.Faculties have explained clearly and they are sound in their field and clear. From the two days training I gained knowledge. I thank the organizers , KSPC, Mr Dubey and others from DMIE, Bhopal for coming here and organizing this class. I feel it as a wonderful opportunity I got. 2 Mr Shaji, Shipyard The two days training is a different experience for me. We are having confined space entry but we do not have a written procedure till now. We are now making procedure. The two days training has been very useful. We will try our best to implement the actions we have learnt from here. I thank the representatives from DMI for extending all the help in conducting this programme. We request DMI to continue such programmes in future also. 3 Sri Jaipal, TCC The training has been very much informative. Most of us have the basics but we tend to forget things in practice and this is a good refresher training. We have the tendency not to follow systems after practicing for few years. So this course has been useful. Few participants from Fire and Rescue Dept are here. We had discussions and they do not have any modern equipment for fire fighting and rescue operation. They have to enter sewers etc but do not have any oxygen meter to check. For them today’s training is a new input. I request DMI to extend whatever possible help to them for getting the required rescue equipment and influence administrative body to get the required items. For them and some of us the two days training is an eye opener giving lot of inputs.