Describe a situation in which an entrant discovers a new hazard within a confined space, explaining the actions required to stop work, re-evaluate the space, and ensure safety before resuming entry operations.

Discovering a new hazard within a confined space requires immediate action to protect the safety of all personnel. A well-defined procedure must be followed to stop work, re-evaluate the situation, and implement necessary controls before resuming entry operations. The key is to prioritize safety above all other concerns, and to have a systematic process in place to deal with unexpected events.

Let’s consider a scenario where a team is performing routine maintenance inside a large, empty storage tank that has previously been cleaned and tested. Two entrants, John and Mary, have entered the tank wearing proper personal protective equipment (PPE), including respirators, and are in constant communication with the attendant outside, Sarah. All atmospheric tests have been previously completed, and the atmospheric readings are all within acceptable limits. The team has followed all proper procedures, and they are working according to the pre-entry plan.

During their work, John is inspecting a previously inaccessible corner of the tank, and discovers a small, corroded area on a pipe that appears to be leaking a liquid. This liquid was not part of the previously identified materials, and it was not anticipated during the pre-entry plan. As soon as John notices the leak, he immediately communicates this discovery to the attendant, Sarah, using their two-way radio, stating "Sarah, this is John, I have found a previously unnoticed leak on a pipe in the south-east corner, the liquid is unknown and I am stopping all work." Sarah immediately alerts the supervisor, Tom, about the situation, stating, "Tom, this is Sarah, John has discovered a new leak on a pipe in the tank, the liquid is unknown and he has stopped work." This clear communication is essential for alerting everyone about the discovery of a new potential hazard. Sarah also instructs John and Mary to move away from the location of the new leak, while she takes action to determine the next steps.

The first action that is required is to immediately stop all work and all entry into the confined space. Tom, as the supervisor, orders Sarah, to implement a full stop work order and to evacuate John and Mary from the tank. Sarah contacts John and Mary, and states "John and Mary, this is Sarah, all work in the confined space is stopped. Please evacuate the confined space immediately, and return to the entry point.” John and Mary immediately move to the entry point and exit the confined space. All work must stop immediately because the discovery of a new hazard means that the confined space has not been completely assessed and there could be additional hazards present.

Once the entrants are safely out of the confined space, the area needs to be isolated. The supervisor Tom, will use barricade tape or other barriers to prevent anyone from accidentally entering the confined space while the hazard is being reevaluated. No one should be allowed into or near the confined space until it is fully re-evaluated and declared safe.

The next step is a full reassessment of the confined space. This means that the confined space will have to be tested to identify the new hazard, and to determine the extent of any risk. In this example, Tom, the supervisor, brings in a qualified industrial hygienist who will identify the source and chemical composition of the leaked fluid. They also do another full atmospheric test, to see if the leak has changed the atmosphere, or if the leak has created any new atmospheric hazards. The team must also fully examine the area around the leak to look for any additional unforeseen or hidden dangers. The reassessment must also include reviewing all previous documentation and permits, to see if the new hazard was mentioned, or if it was ignored by mistake. All new documentation must be properly completed. It must also be determined how much of a risk the new material presents, so proper selection of PPE can be made before work can be allowed to continue. The new plan will also include changes in the ventilation and air monitoring strategies to deal with the new hazard.

After identifying the new hazard, control measures must be put into place before the entry can be resumed. These measures could include the removal of the liquid, using a spill containment kit or a vacuum, or changing the process to avoid the leak area. In this example, the control measure might be to repair the pipe before any more entry is allowed. Based on the new atmospheric testing, and the proper mitigation of the leaked material, the pre-entry plan, the permits, and all training documents, must be reviewed and amended. All changes to the plan must be communicated to all members of the entry team. The new hazards must be explained, and all team members should have an opportunity to ask questions and fully understand the risks before re-entry.

Finally, before any entry is allowed to resume, the pre-entry plan, the permits, and all PPE must be reviewed with all members of the team. A new pre-entry briefing must take place with all team members, and all members must acknowledge that they fully understand the changes. The team must also have completed all necessary training on the new processes, and PPE. Only after all of these steps have been completed, can work within the confined space resume.

In summary, the discovery of a new hazard in a confined space requires a systematic response: immediate cessation of work, evacuation of all personnel, isolation of the area, reevaluation of hazards, implementation of appropriate control measures, and a renewed pre-entry briefing before work can resume. By following these steps, organizations can significantly minimize risks and ensure the safety of all personnel working in confined spaces.