Case Study: Lessons from Confined Space Rescue Operations

Working in a confined space can be a dangerous, but necessary, part of working in certain industries. Confined space work poses various risks to workers and they may encounter dangerous situations, for example flooding, fire, fumes or extreme temperatures. There may also be difficulties in entering, navigating or exiting the confined space. 

Working in a high-risk area, such as a confined space, means that sometimes emergency situations occur where workers may require rescuing. Being prepared, staying calm and ensuring that rescue operations are performed by those who are well trained is critical to performing a safe and successful rescue operation. 

Although each confined space rescue operation is individual and will have unique circumstances, we can use past experience to educate and inform us on best practice and how to make improvements. We can learn lessons from both successful and unsuccessful rescue operations in order to prevent future tragedies and improve outcomes for everyone involved in confined space work. 

In this article, we will look at two very different approaches to worker safety and the impact this can have on the efficacy of rescue operations, as well as the long-term consequences of poor preparation and planning in confined space working.

Understanding Confined Spaces

Working in a confined space means undertaking work in a space that is enclosed or largely enclosed and poses a risk to the worker of:

• Fire
• Explosion
• Loss of consciousness
• Asphyxiation
• Drowning

A confined space is not necessarily a small enclosed, restrictive space. The Health and Safety Executive (HSE) states that working in a confined space could include working in places such as a grain silo, which may have hundreds of cubic metres of capacity but still satisfies the criteria of being enclosed and posing a risk to workers. Other unventilated (or very poorly ventilated) rooms may also be defined as a confined space, regardless of their size.

Confined space working may be necessary for workers in industries such as: 

• Construction
• Manufacturing
• Firefighting
• Mining
• Agriculture
• Search and rescue

Enclosed spaces where workers may have to go to undertake their duties include mines, cave systems, sewers, manholes, tanks, silos, pipelines, crawlspaces, underground vaults etc. 

According to information published by the HSE, a number of people are killed or seriously injured in confined spaces each year in the UK. If people working in a confined space get into difficulty, those tasked with rescuing them are also at risk from dangers and hazards. It is crucial that if someone needs rescuing from a confined space the correct procedures are followed and that rescuers are well trained and have access to the correct equipment. 

In this article, we will compare and contrast two real-life confined space rescues and discuss the lessons that can be learned from each of them. We will explore key lessons learned from these operations as well as what ‘best practice’ looks like when it comes to confined space rescue operations. Finally, we will explore future trends and innovations within this area. 

Case Study One: Mining Industry

In 2010 in Chile, 33 workers were rescued from the San Jose gold and copper mine. The mine, opened in 1889, had collapsed on 5th August 2010, following disturbances earlier in the day. Numerous other accidents had occurred in the mine. In 2007 a fatal explosion occurred killing three miners. Despite this, little was done to improve conditions before the mine was reopened and authorised for continued excavation by Chile’s National Geology and Mining Service (Servicio Nacional de Geología y Minería; Sernageomin) in 2008.

A local rescue squad initially attempted a rescue but were unsuccessful. Following this, the Chilean government told the mining company itself to organise search and rescue efforts. On 7th August a second collapse occurred. This collapse blocked access to ventilation shafts that might have served as a point of egress if ladders had been in place as required by safety regulations. (“Chile mine rescue of 2010 | Description & Facts | Britannica”) 

The next day rescue workers began drilling exploratory holes through which they sent listening probes in an attempt to discern signs of life. Outdated maps of the mine’s structure made the search and rescue efforts even more difficult. 

On 22nd August, one of the probes detected tapping, and when it was brought up to the surface, a note had been attached saying “Everything is okay” in Spanish. A video feed was threaded through a small drill hole which later confirmed all of the men were still alive.

Initially, in the more than two weeks underground without contact with rescuers, the men had to live off rations that were only meant to last two days and drink water obtained from a spring and a radiator. 

The day after the probes detected life, water, nutrient gel and communication devices were passed through the holes to the survivors and a group of experts including mental health professionals and those from NASA joined the efforts to keep the men alive and well. Throughout the following days the men were sent essential items such as solid food, lighting equipment and first aid supplies.

Three separate machines were brought to the site; two were raise-bore machines, which drill a small hole and then widen it, the other was a piece of equipment normally used in oil and gas prospecting that could drill one wide hole. The three were used to make separate drilling attempts dubbed plan A, B and C. The trapped men were split into three groups to remove debris caused by the drilling and reinforce the walls of the mine to prevent further collapse.

On 9th October, one of the raised borers managed to complete the drilling of a tunnel to an accessible chamber. The top of the shaft was then lined with special metal tubing so that the men could be brought up to the surface in a special metal capsule.

On 12th October, a rescue worker was lowered down into the mine inside the metal capsule. By the end of that evening, all of the miners had been rescued after 69 days underground.

Although the mining company had been ordered to coordinate the rescue, they did not have the funds to pay the almost $2 million that it cost, forcing the Chilean government and its companies to step in. They would later reimburse some of this money. 

Although the men had emotional reunions with their families and enjoyed some fame as a result of their ordeal, many ended up with long-term mental health problems from the trauma of their ordeal and some turned to abusing drugs and alcohol to cope.

Case Study Two: Manufacturing Sector

Unlike case study one, our second case study shows a proactive approach to prevention and planning to protect workers and reduce risks.

After conducting a risk assessment, the managers of a large manufacturing facility that specialised in chemical production and storage, decided to partner with a professional confined space rescue team, to ensure the safety of their workers. 

The facility had several confined spaces within its premises, including tanks, silos and tunnels which required routine maintenance and inspection. Their risk assessment noted several hazards that this presented including:

• The space had limited access making entry and egress difficult
• There was the potential for toxic gases
• The space had unpredictable working conditions

As a result, they decided controls needed to be put in place:

• Testing and monitoring for toxic gases like hydrogen sulphide (H2S) and methane (CH4) were crucial
• Communication within confined spaces was difficult due to the physical constraints and noise levels, requiring specialised communication equipment

They also realised that:

• In the event of an accident or injury within the confined space, rapid medical response was essential

A decision was made to partner with a professional Risk Management Service, which had specialist equipment and specially trained staff to deal with confined space rescue operations. They offered services including:

• Preparation and planning
• Specialist communication, monitoring and access equipment
• Training and drills

By partnering with a professional Risk Management company, the manufacturing plant was able to improve compliance and enhance worker safety. This gave everyone peace of mind that should an incident occur, they were well equipped to deal with it safely and efficiently.

If you would like to read the full case study or learn more about the Risk Management company that the manufacturing plant partnered with, you can find this information here. 

Key Lessons and Best Practices

We can learn lessons from real-life examples of confined rescues when they are successful, as well as when they go wrong.

In the Chilean example, we see that early warning signs were ignored and fatalities had already happened in the same area previously. Despite this, little was done to improve the conditions before the mine was reopened. There is also no mention of a risk assessment ever being conducted. Although strengthening rescue operations is crucial to protecting life, preventing accidents and incidents from occurring in the first place is even more important. 

Maps of the area were also outdated which made rescue efforts more difficult, dangerous and slower.

The mining company did not have an immediate emergency response team, initially relying on local services that were not equipped for such a task.

Although physically okay, the psychological effects of being trapped in a confined space had a serious effect on the miners. It is vital that mental health support is also given after confined space rescue.

To recap, key lessons for improvement include:

• Always conduct a risk assessment before confined space work begins to identify hazards and put procedures in place to control the risks
• Follow regulations, in this case the ladders were not in the right places for emergency egress
• Make sure up-to-date plans and maps are available of any confined space before work starts
• Spot early warning signs to avoid putting workers at risk
• Never prioritise money or productivity over worker safety
• Always secure a site after an incident has occurred and don’t reopen it until it is safe and structurally sound
• Learn from mistakes and precedents and make improvements, rather than hoping it won’t happen again
• Have an emergency rescue plan in place (including training, partnering with professional services, practising for critical incidents etc)
• Provide sufficient rations in case of getting trapped (in this case the miners only took two days’ worth), especially the nutritional gel which did not arrive until two weeks after the collapse

Positive aspects of the case study:

• The miners showed incredible resilience
• A cohesive and collaborative effort involving multiple agencies was able to be coordinated quickly through the event getting international coverage
• The use of multiple plans for rescue (A, B and C) improved the odds of reaching the men in time
• Some mental health support for the men was provided initially
• Good use of technology, e.g. the video probes, specialist metal tubing and casing

From the second case study, we can see a very different approach to confined space working that focuses on prevention and planning. The company conducted a detailed risk assessment, noting multiple hazards and seeking ways to control them. Based on the findings of their risk assessment, management put in place effective controls to protect workers in case of an incident. They were willing to make a financial investment in employing professional services to protect the safety of their workers. 

Key lessons to recap:

• Planning and preparation are key in ensuring the safety and wellbeing of workers
• It is vital to conduct risk assessments and put controls in place
• Partnering with a professional company improves safety, efficiency and compliance

Possible improvements and lessons learned:

• The facility did not say whether they had explored if risks could be reduced in other ways, for example changing their working practices
• Although having a professional company on hand is useful, it is also of fundamental importance that in-house training is done for emergencies and not to get complacent by relying on partners
• Using technology, such as drones and robotics to perform testing and routine maintenance could negate the need for workers to enter some of the confined spaces in the plant

Future Trends and Innovations

Innovative technologies are likely to completely reshape the landscape of confined space work and rescue operations. Implementing new technologies can help to improve safety and compliance if used properly.

Artificial intelligence

Artificial Intelligence (AI) is increasingly being implemented across all sectors. AI has the potential to improve and modernise the search and rescue process. AI is highly effective in analysing patterns and making predictions using data and information.

AI systems can analyse and interpret vast amounts of data quickly and accurately. This can help people ascertain the risks associated with a particular area or job and put in necessary controls to keep everyone safer. 

AI also has a role to play within physical search and rescue operations. Drones and UAVs (unmanned aerial vehicles) that use AI algorithms can be useful in navigating complex or difficult to access locations and environments to search for missing or endangered workers. 

Innovations in technology can help improve emergency responses:

• By analysing real-time data quickly and accurately
• By providing alerts and early warning systems
• By helping to coordinate rescue and relief responses efficiently

Developments in robotics

Robots may also play a role in the future of search and rescue operations, including those in confined spaces. It is possible that with improvements in robotic technology, robots may replace workers in particularly unstable atmospheres or tight spaces. This will prevent people from having to put their lives at risk by doing dangerous tasks in the first place.

Confined spaces may be poorly lit and unsafe to enter for long periods of time due to their temperature, air quality or other hazards. Drones and robotics are able to enter these areas to identify anomalies, take samples or perform routine maintenance. They may also be used to identify the location of casualties after an incident more quickly. This allows search and rescue teams to focus on retrieving people safely without having to spend time searching and potentially putting themselves at greater risk. 

Virtual reality and simulation

Virtual reality and simulation provide an immersive experience that allows for better planning, preparation and navigation of confined spaces. By using virtual reality or simulation, workers can explore the areas they will be working in before they go inside, which can help them to plan for safe entry and egress and familiarise themselves with the terrain. It can also help with planning and training exercises, such as:

• Emergency protocols
• Communication methods
• Identifying hazards

Smart sensors and monitors

Poor air quality in confined spaces poses a significant risk to workers who may be affected by a lack of oxygen, toxic substances, dust or other hazardous vapours. Smart sensors and monitors are able to continuously check air quality in confined spaces and wirelessly communicate the results. This allows for data collection and analysis in real time and may allow for alarms to be raised more quickly and emergency protocols (such as ventilation) to be triggered instantly.

Conclusion

Working in confined spaces can pose multiple risks to workers and steps should be taken to reduce these risks when possible. In this article we looked at two very different approaches to worker safety, one which disregarded worker safety and only acted after the event and one which took preventative steps to ensure they were prepared for any critical incidents.

Embracing new developments in technology should improve worker safety and make search and rescue operations easier, safer and more effective. Technology should always be used in collaboration with well-trained and competent humans rather than as a primary source of assistance. Preparedness and planning are key in confined space rescue operations to avoid complacency, knowledge gaps and errors.