BSP-02-Standard-1633 - Blasting and Painting (Mod 32, Rev. 2.0)

HSE STANDARD Module 32 Blasting and Painting

THIS DOCUMENT CONTAINS ONE MODULE IN A SET COMPRISING HSE STANDARDS FOR THE BRUNEI SHELL COMPANIES

May 2000

Approved by: SCO Document Owner: HSE

Revision

2.0

IMPORTANT NOTICE This module is one of a series produced by Brunei Shell Petroleum Company Sdn Bhd. They represent the minimum acceptable HSE standards for a wide range of operations that are carried out by, and for, the Brunei Shell Companies (BSC). Brunei Shell Companies or BSC are expressions used for convenience when referring to Brunei Shell Petroleum Company Sdn Bhd (BSP), Brunei LNG Sdn Bhd (BLNG), Brunei Shell Marketing Company Sdn Bhd (BSM) and Brunei Shell Tankers Sdn Bhd (BST) collectively. BSC is not a legal entity. Each of the four companies has its own separate legal identity and objectives. The Government of Brunei Darussalam and Shell (which is also an expression of convenience) are shareholders in all four companies, whilst there is a third shareholder in BLNG, namely Mitsubishi Corporation.

THIS DOCUMENT Comment and feedback from users of this module is encouraged, in order that the series may be updated as appropriate to reflect current requirements. & HSE Standards Master Index, Module 00, document number TMS0434 which is republished at regular intervals. This document is unregistered. Brunei Shell personnel should obtain copies in accordance with the procedure in HSE Standards Master Index, Module 00, , Chapter 4. Contract personnel should obtain copies from the Contract Holder. Within the Corporate Management System (CMS) documentation hierarchy, this document has the status of Standards and its Process Owner is Head of HSE.

DISCLAIMER Brunei Shell Petroleum Company Sendirian Berhad assume no liability for the contents of this module, in whole or in part, nor for interpretations made by the user. The objective of the module is to provide sound working practices and standards, and thus to provide for better management of health, safety and environmental matters.

Module 32 - Blasting and Painting

Contents 1.

INTRODUCTION

4

2.

REQUIREMENTS

5

2.1

Blasting and Painting Personnel

5

2.2

Equipment

6

2.3

Materials

7

2.4

Activity Controls

8

3.

REFERENCES

13

4.

APPENDICES

14

Appendix 1 - Safety Responsibilities

14

Appendix 2 - Correction Factors for Pellistors in Gas Test Meters

15

THE BRUNEI SHELL COMPANIES May 2000

HSE Standard Page 3 of 16

Module 32 - Blasting and Painting 1.

INTRODUCTION The inter-related activities of blasting and painting are carried out extensively on virtually all BSC assets and are done to renew, restore and maintain the surface coatings which protect structures, plant and equipment from corrosion and damage. Blasting is done by entraining special abrasive in an airstream and directing that stream against the surface to be prepared, in the process removing existing coatings, corrosion and scale. Painting uses materials, often containing volatile solvents, pumped at high pressures to apply coatings to surfaces prepared by blasting or by other means such as washing or wire brushing. There are obvious hazards associated with both activities and they include the following: injury risk from the blasting and painting processes. injury risk resulting from blasting holes or exposed in live pipelines. health risk from exposure to harmful substances. flammable atmospheres from spray painting processes. ignition sources from discharged static electricity. Application of the standard in this document will protect personnel from the inherent risks associated with blasting and painting activities, and will ensure appropriate controls are in place to properly manage known risks. This standard covers all aspects of blasting and painting wherever it is carried out and follows the basic structure shown below: the people involved the equipment used the materials used activity controls Note that the only type of blasting referred to in this module is the type described above. Another type of blasting, in which water is pumped at very high pressure through jets, is separately covered in Module 25 - High Pressure Water Jetting. The Process Owner of this module is SCO (EPM, SES/3, LEN)




2.

REQUIREMENTS

2.1 Blasting and Painting Personnel Only competent personnel employed by a company on contract to BSC shall normally carry out blasting and painting activities on behalf of BSC. Before being employed to carry out these activities, personnel shall demonstrate their competence through successful completion of a Trade Test conducted under the supervision of the Contractor. Blasting and painting personnel (hereafter referred to as painters) shall be trained to standards approved by BSC and this training will be carried out at recognised training establishments. Personnel employed by a company on contract to BSC shall meet the requirements for each job category as shown in Table 1. Table 1 - Personnel Requirements -2%&$7(*25<

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2.1.2 Personnel Records Personnel records of painters shall be maintained and kept up to date by the contractor and be available for inspection by BSC on request. For each employee, records shall show: Full name Date of birth Job category Training completed with certificates awarded (originals or certified copies) Brunei IC or Passport number Offshore Pass number (if relevant) Date of last medical check (for personnel continuously engaged in painting works)




2.2 Equipment Equipment manufactured to known and accepted standards shall be used and valid test and inspection certificates shall accompany all air receivers, blasting pots, pressure hoses and paint pumping units. Inspection certificates shall be made available for inspection by BSC on request. Compressed air supplies for blasting equipment and paint pumping units shall be free from entrained water and oil and should not exceed a temperature of 110 degree C at air receiver inlets. Adequate separators and traps shall be provided in compressed air systems and these should be installed in the coolest parts of the systems. They shall be emptied regularly to prevent carryover and air receivers shall be periodically drained down. Blasting hoses, whatever type of hose connector is used, shall either have their connectors mechanically wired together or have secondary hose end retaining or locking devices fitted to retain the hose end in the event of primary connector failure. In addition, blasting pot bottom hose couplings shall be fitted with safety slip wires. The use of swivel-action locking clamps in any part of a hose assembly is not permitted. Lay patterns for hoses shall avoid tight radius bends and kinking. Paint hoses shall be hydrostatically pressure tested at periods not exceeding 3 months. The test pressure shall be 1.25 x maximum working pressure and a satisfactory test must show no significant pressure loss over a period of one minute. Hoses which show bulges or cracks shall be discarded. Test results shall be recorded and be available for inspection by BSC on request. Hoses shall be clearly marked with their pressure ratings. Blasting guns shall be fitted with deadman shutoff triggers. When the hose carrying the abrasive and air stream to a blasting gun is longer than 60m, an automatic actuated shutoff device shall be installed at the blasting pot end of the hose. Defeating the deadman facility on blasting guns by securing the trigger in the ON position is strictly prohibited. Paint sprayguns shall be fitted with deadman shutoff triggers and fan protection devices. Defeating the deadman facility on sprayguns by securing the triggers in the ON position and/ or operating a spraygun without the fan protector in place is strictly prohibited. All objects or structures to be blasted and painted shall be electrically bonded to suitable earth points. To prevent the buildup of static electricity and the possible discharge of a spark, all components in a blasting system (air compressors, air receivers, blasting pots, hoses and guns) and a painting system (air receivers, paint pumps, hoses and guns) shall have electrical continuity and shall be electrically bonded to the objects or structures being blasted and painted or to suitable earth points. Air moving equipment (fan units and inductors) shall also be electrically bonded to suitable earth points and it shall be measured to confirm proper conductivity otherwise it shall be bonded with a separate earth wire. The paint spray hose shall be a semi-conductive material and the electrical resistance across earth points shall not exceed 1 Mohm. Resistance tests shall be carried out at the start of work, at daily intervals and each time a new connection is made. Test results shall be recorded and entered in daily reports. All equipment shall be kept clean, properly maintained and stored under cover when not in use. Hoses should be coiled to prevent damage. Daily, systematic inspection of all components in blasting and painting systems shall be carried out before putting the equipment into service.




2.3 Materials 2.3.1 Storage of Blasting Materials Abrasive for blasting is normally supplied in 25 kg paper sacks and 2 tonne bags made from reinforced fabric. All abrasive supplies shall be stored in designated storage areas which shall be capable of supporting the loadings applied by the total weight of abrasive in store. Where the total load applied may exceed the permissable loading, warning signs shall be erected and regular checks carried out by supervisors to ensure an unacceptable build-up does not occur. Abrasive supplies shall be kept dry to prevent excessive deck loadings from the added weight of water. 2 tonne abrasive bags shall be lifted using only certified 4-leg slings attached to the lifting points on the bags. Personnel directly involved in lifting 2 tonne abrasive bags shall be properly trained in appropriate rigging techniques. Bags and sacks shall be pyramid-stacked to prevent toppling and shall not block access ways. Storage areas and the areas around blasting pots shall be kept clean and tidy with sweepings of grit properly disposed of using empty sacks and bags. Proper manual lifting techniques shall be used to prevent personal injury when moving sacks of abrasive. 2.3.2 Storage of Painting Materials All painting materials including paint, solvents, thinners, additives and cleaners shall be stored in a non-enclosed area remote from sources of heat and combustion and protected from direct sunlight. In areas where major painting projects are undertaken, materials storage shall be in a dedicated paint storage container fitted with explosion proof light fittings and a fire extinguishing system. Portable fire extinguishers shall be kept in the immediate vicinity of paint containers and areas where significant amounts of painting materials are stored. Access to paint storage areas shall only be made in accordance with an entry procedure and a notice of this requirement shall be displayed at the entrance to these areas. All materials shall be contained in manufacturers original containers, durably and legibly marked with descriptions of the contents. This shall include the specification number, colour reference number, method of application for which it is intended, batch number, date of manufacture, manufacturer's name, initials or recognised trade mark, and any specific storage instructions. Materials Safety Data Sheets (MSDSs) or Safe Handling of Chemicals (SHOC) information shall be available for all painting materials. Materials shall be stored in accordance with manufacturers special instructions or procedures and any stipulations set out in MSDSs and SHOC cards. Incompatible volatile substances shall be segregated. Unidentified or expired painting materials shall neither be accepted into storage nor kept in store. Proper manual lifting techniques shall be used to prevent personal injury when moving containers of painting materials.




2.3.3 Transfer, Mixing, Thinning and Application of Painting Materials Plastic containers shall not be used for transferring, mixing, thinning or applying painting materials. When transferring solvent from a metal drum into another container, the drum shall be electrically bonded to the container using a suitable cable and clamps. There shall be no intermixing of different types of paint. When mixing, thinning and applying paint, manufacturers instructions or procedures shall be followed and any specific information from MSDSs or SHOC cards taken into account. If specified or if necessary, appropriate personal protective equipment shall be supplied and worn in accordance with the relevant sections of HSE Standards Module 02 - Personal Protective Equipment and Module 07 - Confined spaces.

2.4 Activity Controls 2.4.1 Work Permits Blasting and painting in live production areas, onshore and offshore, shall only be carried out under permit control and shall be in full conformance with the requirements of the permit to work system, HSE Standard Module 03 - Permit to Work Procedure. Where required, Hot Work Permits shall be obtained for the operation of internal combustion, engine-driven air compressors and for abrasive blasting, needle gunning, powered wire brushing and pressure paint spraying. For all other activities related to blasting and painting in a production area, Cold Work Permits shall be required. Work permits are not required for blasting and painting in areas designated for that specific purpose, e.g. blasting and spray booths and approved areas in onshore fabrication yards. 2.4.2 Equipment Protection Abrasive blasting shall not be carried out near certain items of equipment unless all such items in the area of activity have been protected and the protection approved by the Asset Holder. Examples of equipment items requiring protection are: running machinery engine and ventilation system air intakes valve spindles and actuators instruments instrument gas pipework glass and glass-faced guages light fittings electrical cables cable trays stainless steel pipework control desks and panels equipment identification plates structures made of synthetic material, e.g. glass-reinforced plastic sheds




Screens shall be placed to prevent abrasive and dust from abrasive blasting operations affecting nearby buildings, installations, roads, etc. The Contractor shall ensure the protection of equipment. If adequate protection cannot be achieved, the area will be considered unsuitable for abrasive blasting operations and alternative methods of surface preparation employed, e.g. needle guns, solvents, wire brushes and chipping hammers. The requirements for protection shall also apply during painting and the Contractor shall ensure equipment protection against paint splashes and overspray. Wherever possible, spray painting shall be carried out at a safe distance from other occupied areas, buildings and carparks. Worksites shall be barriered off and warning signs placed at boundary limits. Firefighting capability shall be provided e.g. portable fire extinguishers dry chemical type placed in the vicinity of air compressors and abrasive blasting and painting worksites. 2.4.3 Height Access When access to blasting and painting workfaces is provided by conventional scaffolding, only structures certified by a scaffolding company on contract to BSC shall be used. The Contractor shall ensure that an accurate requirement for scaffolding is identified in advance of it being needed. The intended use and loadings will require to be clearly specified (refer to HSE Standard Module 06 - Scaffolding and Access). Before start of work each day, Painting Supervisors shall check that the green faces of the SCAFFTAGs on scaffold structures are showing and that the weekly scaffold inspection record is up to date. When working on scaffold structures, painters shall ensure: materials are raised and lowered using ropes. Do not throw them. materials are not stacked higher than working platform guardrails. access ways are kept clear at all times. working platforms are not overloaded; allowance shall be made for the added weight of spent grit. temporary lighting, if required, is suitable for flammable atmospheres and is working properly. ladders are secure and used only for working platform access. wheels on mobile towers are locked before men go on the tower. scaffold to be earthed to avoid static charges build-up. Approval for height access using means other than conventional scaffolding will require to be obtained from line supervision prior to execution of the work.




2.4.4 Personal Protective Equipment Abrasive Blasting The action of abrasive blasting produces flying abrasive, debris and dust in the immediate vicinity of the activity and operators must be provided with and use appropriate protection against these hazards. In addition to the personal protective equipment requirements for boots, coverall, upper body protection and gauntlets, protection shall be given by the use of air-fed helmets with a constant supply of breathing quality air. The addition of an air cooler to maintain the air supply within an acceptable temperature range is strongly recommended. Also recommended is the use of visor outer surface 'tear-offs' in acetate or similar material to enable operators to maintain full visibility. Painting The action of spray painting produces airborne paint particles in the form of a mist which can cause irritation to the eyes, nose, throat and lungs and may possibly lead to more severe health problems. As well as the basic personal protective equipment requirements referred to previously, protection for painters shall be given in open air and confined space circumstances as follows: Open air Filter mask or cartridge type respirator and shielded or baffled goggles. Confined space Air-fed helmet. For full details of all requirements for personal protection, refer to HSE Standards Module 02 - Personal Protective Equipment. 2.4.5 Confined Spaces Full details of the requirements for working in confined spaces are given in HSE Standards Module 7 - Confined Spaces. In addition to these requirements, the following points shall be observed: Ventilation of confined spaces must be sufficient to ensure all parts of the work site are adequately ventilated. Particular attention must be paid to tank and vessel bottoms where heavier-than-air vapours may accumulate. Paint solvents have different characteristics to hydrocarbon gases. Since gas test meters are calibrated to methane,readings taken in an atmosphere contaminated by the base constituent of the paint solvent in use, e.g. toluene, xylene, must be subject to an appropriate conversion factor to give a more accurate LEL percentage. For information on correction factors, see Appendix 1. Solvent absorbent filter masks may be used by inspectors and visitors to the work site provided a separate test is carried out with a certificate issued prior to entry and their exposure is: no more than 5 minutes per occurence and no more than an accumulated 30 minutes per day. Operating and maintenance instructions for air-fed helmets and instructions for total use time of solvent absorbent filters must be available on site.




Limit the number of painters inside confined space to avoid air-fed hose entangling. Solvent absorbent filter masks must be discarded and properly disposed of after use total use time has expired. When solvents are being used, Self Contained Breathing Apparatus Escape Sets (10 minute type) must be kept immediately available just outside the confined space. Sufficient pneumatic lighting must be provided to ensure clear access way for blasters and painters performing the work. 2.4.6 Work on Live Systems Live systems are hydrocarbon production systems, offshore and onshore, comprising wells, pipework and vessels through which oil and/or gas is, or may be flowing. Offshore, work on live systems happens frequently and is carried out in accordance with the policy and procedures for Concurrent Production and Painting Activities (CPPA), document reference TMS0569. Work on live systems onshore happens regularly and is controlled through application of the Permit to Work Procedure. In either case, work on live systems shall be carried out only if: abrasive blasting and painting can immediately be stopped for operator access to the facility or when the wind direction is unfavourable. the state of corrosion of the facility does not present a significant danger. Recent NDT inspection reports may provide valuable information which can be used to help decide whether blasting should proceed. there are no spark producing operations in progress, e.g. grinding, welding, etc. there are no turbine, engine, compressor or ventilation intakes in the immediate work area. operators can quickly and easily reach kill buttons and switches. The Asset Holder shall decide whether it is safe to keep systems live while abrasive blasting, power cleaning or painting is carried out. After permission to carry out these activities has been given, the Asset Holder shall have the responsibility to ensure the continuing safe condition of the facility. 2.4.7 Health and Hygiene The information provided on MSDSs and SHOC cards is designed to protect the health of persons working with the substances and shall always be observed. If paint spray is inhaled, penetrates the skin or enters the eyes, medical attention must be obtained immediately. Also, any unusual effects experienced during painting such as dizziness, nausea or a burning sensation in the eyes shall be reported to a Painting Supervisor immediately and medical attention obtained. In all cases of medical attention being needed, an Incident Report (Omnisafe) shall be raised in accordance with HSE Standards Module 30 - Incident Classification and Reporting, Module 31 - Incident Investigation Procedures. Where there is a risk of solvent splashes on the skin, wash it down thoroughly with running water and barrier creams should be applied and gloves worn. The use of thinners, solvents or similar substances for removing paint from the skin is prohibited and wherever possible, proprietary skin cleansers should be used.




2.4.8 Safe Practices Safety shall be ensured through the following practices: Operate equipment at the lowest pressure necessary to achieve the required quality. Never exceed the Safe Working Pressure of the equipment. Conduct compressor air supply breathing air tests for carbon monoxide, carbon dioxide and oil mist not exceeding recommended value for health risk protection. Drain down the filter used in the breathing quality air supply to air-fed helmets. A slight, continuous drain from the drain on the bottom of the filter body is recommended. Carry out servicing or adjustment of equipment only after it has been depressurised. Release the system pressure, close all isolating valves and open drains and vents before disconnecting any part of the system. Never point a blasting or spray gun at a person. Check that the spray gun fan guard is in place before spraying. Always engage the trigger safety catch when work is interrupted. Always carry a blasting or spray gun by the handle with fingers removed from the trigger. Clean up any spillage of abrasive, paint, thinners, solvent and detergent immediately it occurs and dispose of cleaning material correctly. At offshore locations, establish and maintain radio communication between the barge or work boat and the Painting Supervisor on the platform. Maintain good housekeeping on platform and vessel at all time.

Maintain good housekeeping on platform and vessel at all time.




3.

REFERENCES UK Legislation &

Health and Safety at Work etc. Act 1974

British Standards &

BS 2092 Eye Protection

BSC/BSP Documents &

HSE Standards Module 02 - Personal Protective Equipment

&

HSE Standards Module 03 - Permit to Work System

&

HSE Standards Module 06 - Scaffolding and Access

&

HSE Standards Module 07 - Confined Spaces

&

HSE Standards Module 30 - Incident Classifications and Reporting

&

HSE Standards Module 31 - Incident investigation Procedures

&

HSE Standards Module 40 - Occupational Health

&

HSE Standards Module 50 - Register of Environmental Legislation, Standards and Other Requirements

&

HSE Standards Module 51 - Waste Handling Procedure

&

HSE Standards Module 52 - Environmental Assessment

&

Policy and Procedures for Concurrent Production and Painting Activities (CPPA) Document Number TMS 0569, Revision 0, July 1994

&

Engineering Specification ES-48.00, Issue No.5, December 1993 Specification for Painting/Coating of Production and Processing Facilities




4.

APPENDICES

Appendix 1 - Safety Responsibilities Painting Supervisors shall be responsible for: ensuring personnel working with and handling blasting and painting materials have received adequate information, instruction and training, and meet the requirements set out in Section 2.1. ensuring correct procedures are followed for transferring, mixing, thinning and application. making all personnel aware of the hazards associated with the substances being used. ensuring the use of appropriate personal protective equipment when needed. obtaining any permits necessary before start of work. ensuring the use of proper manual lifting techniques to prevent personal injury. ensuring spills are promptly dealt with in accordance with instructions in the MSDSs/ SHOC cards or on the substance container, and reported. arranging proper disposal of materials from spills cleanup. proper earthing of spray equipment and verification of earthing conductivity value prior paint spraying work. Painters must ensure: no smoking, eating or drinking during materials transfer, mixing, thinning and application, or at any other time at the work site. personal hygiene by thorough washing of hands after materials handling. no syphoning of liquids by mouth. no transfer of materials into unmarked or non-metallic containers. immediate reporting of emergencies to their supervisor. the blasting and painting work in a safe, efficient manner follow the required procedure and standard as directed by the Painting Supervisor. responsible for good housekeeping inside paint stores. report any unsafe condition and near miss to immediate supervisor. ensuring that all waste oil, paint, thinner, etc. to be sent ashore and properly documented recorded.




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DOCUMENT CHANGE PROPOSAL FORM This form provides a tool for the Line to propose changes. It is to be sent to the Document Owner for action/response and copied to HSE.

Affected Document Document Title: Document ref: TMS

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Revision: 2.0

Dated: May 2000

BSP-02-Standard-1633 - Blasting and Painting (Mod 32, Rev. 2.0)

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