SCENARIO

You and your group work for an automotive company that has a regular maintenance shutdown in the first two weeks of July every year. This shutdown coincides with the annual maintenance shutdown that the Tier 1 suppliers of parts to the auto manufacturers also take. This annual shutdown allows your company and all automotive parts suppliers to perform non-regular maintenance, upgrades, and service to equipment, machinery, and process vessels. For the upcoming shut-down cycle, the underground "wash-pits," where the sludge and waste from the robotic painting lines dump their waste and run-off, need to be cleaned and inspected. This job only occurs every three years and it has to be done manually by workers. These wash pits contain paint residue and solvents such as methyl ethyl ketone and toluene.

The pits are large underground vaults where an extension ladder is used for access and egress. The pits are approximately 20 m by 20 m wide and 5 m deep. There is no light in the pits; therefore, workers need to carry a light source with them. There are two hatches that get removed, both 1.5 m wide, at opposing ends of the pits where the access ladders will be located.

Your companys confined space program has not been updated in 4 years. The Director of Operations has asked that you look over your confined space program and write an entry and rescue plan outlining:

hazards that the workers entering will likely face (use sound judgment and extrapolate what the hazards may be based on the information provided),

air testing requirements

training requirements for the job, and

what rescue procedures need to be in place before entry begins