Confined Space — Tank Entry SWMS

Tank entry in manufacturing facilities involves entering process tanks, mixing vessels, storage containers, and reactor vessels for cleaning, inspection, maintenance, and repair. Chemical residues from previous contents create atmospheric hazards including toxic vapours, oxygen depletion, and flammable gas accumulation. Many manufacturing tank entries involve substances that have been heated, reacted, or mixed, meaning residual atmospheres may be complex and unpredictable. The WHS Regulation 2025 requires a permit-to-work system for all confined space entry with continuous atmospheric monitoring and a documented rescue plan. This template maps controls to the binding Confined Spaces Code of Practice effective 1 July 2026.

Legal Requirements

regulation

WHS Regulation 2025 Part 4.3 — Confined Spaces

hrcw category

Work in a confined space

code of practice

Confined Spaces (binding 1 July 2026 under Section 26A)

section 26a binding

Yes — effective 1 July 2026. Non-compliance is admissible as evidence of breach.

Hazards

Hazard	Consequence	Likelihood
Toxic vapour from chemical residues in tanks and vessels	Acute poisoning, loss of consciousness, death	Possible
Oxygen depletion from chemical reactions or inert gas blanketing	Asphyxiation, death	Possible
Flammable vapour accumulation from residual solvents	Explosion, severe burns, death	Unlikely
Chemical skin contact with residues on tank surfaces	Chemical burns, skin sensitisation	Likely
Falls from tank access ladders and internal structures	Fractures, head injuries	Possible
Engulfment in residual material or incoming product	Suffocation, death	Unlikely

Controls (Hierarchy of Controls)

Implement a confined space entry permit system with atmospheric testing before and during entry

Isolate all inlets, outlets, and agitators using lockout tagout before entry

Purge tanks with fresh air and verify atmospheric safety before entry using calibrated multi-gas detector

Conduct continuous atmospheric monitoring for oxygen, flammable gases, and toxic gases throughout entry

Provide supplied-air breathing apparatus for entries where atmospheric hazards cannot be fully eliminated

Assign a trained standby person at the entry point with rescue equipment and communications

Develop tank-specific rescue plans with trained rescue team and equipment

Provide chemical-resistant PPE for workers entering tanks with chemical residue potential

Recent Prosecutions

Orica Australia Pty Ltd$1,200,000

Workers exposed to hazardous atmospheres in industrial operations without adequate controls or monitoring.

2024 — SafeWork NSW v Orica Australia Pty Ltd [2024]

SafeWork SA prosecution$840,000

Worker death during manufacturing operations with inadequate confined space and equipment procedures.

2024 — SafeWork SA Manufacturing Prosecution [2024]

What Your SWMS Must Include

✓Confined space entry permit with pre-entry atmospheric testing requirements

✓Lockout tagout procedure for all inlets, outlets, agitators, and energy sources

✓Continuous atmospheric monitoring plan with gas detector calibration schedule

✓Tank-specific rescue plan with trained rescue team and equipment

✓Chemical residue identification and PPE selection procedure

Need a compliant Tank Entry SWMS?

Our WHS consultants build tank-specific SWMS that address atmospheric hazards, chemical residues, and rescue planning for your confined space entries.