KOC.sa.030 - Painting and Coating HSE Procedure

Painting & Coating HSE Procedure Page 1 of 7

Painting & Coating HSE Procedure Document Number: KOC.SA.030 Approver: (Technical) Approver: (Administrative) Scope:

Manager Ahmadi Services

All KOC Directorates

Document Coordinator: Control Tier:

Issue Date:

May 25, 2009

Issuing Group:

HSE Group

Revision / Review Date:

May 25, 2009

Next Review Date:

May 24, 2010

Manager (HSE)

Author:

TL Safety TL Standards 3

1.0 Purpose/Scope The purpose of this document is to provide guidance and outline responsibilities associated with the safety of all painting and coating works carried out at all areas under KOC jurisdiction. The document describes the principal requirements of painting & coating safety and to ensure that safe working practices are followed for painting & coating work by concerned KOC and Contractor’s employees in compliance with relevant standards.

2.0 Definitions Painting area - Any area where flammable vapors, mists or combustible residues, dusts or deposits may be present due to painting / coating operations. Spray booth - An enclosure containing a flammable or combustible spraying operation and confining and limiting the escape of paint, vapor and residue by means of a powered exhaust system. Flammable Materials - In paint systems, it is normally the organic solvent vapor that is flammable. All the solvents (except for the water based paints) present a fire hazard. Flash Point - The lowest temperature at which a liquid will give off sufficient vapor to ignite when exposed to an open flame. The danger of fire exists virtually always when solvents are in use. Flammable (Explosive) Limits - The range of vapor/air concentrations that are potentially explosive. The lower flammable (explosive) limit (LEL) is typically on the order of 1% to 2% by volume, a level readily obtained in the area near opened solvent containers and near the nozzle of a spray painting gun in operation. Permissible Exposure Limit (PEL) - The maximum amount or concentration of a chemical that a worker may be exposed to under OSHA regulations. Threshold Limit Value (TLV) - A time-weighted average concentration under which most people can work consistently for 8 hours a day, day after day, with no harmful effects.

Control Tier: 3

Revision Date: May 25, 2009 Uncontrolled Copy. Valid Only at the Time of Printing: 10-Jun-09

Painting & Coating HSE Procedure Page 2 of 7

3.0 General Requirements •

KOC HSEMS Element HSE-05-2

4.0 Key Responsibilities Worksite Supervisor •

Will ensure that all painting and coating works are carried out in a safe manner by suitably trained and competent personnel in accordance with defined safe working practices and procedures.

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Ensuring that necessary work permit along with Job Safety Analysis (JSA) are secured & posted at the jobsite and all specified precautions are implemented.

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Ensuring that personnel carrying out the work are utilizing the proper PPE.

Permit Authorities (Issuer & Applicant) •

Ensuring that all the risks and hazards have been identified through Job Safety Analysis (JSA) and authorized under appropriate work permit prior to commencing the task.

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Ensuring that all personnel involved in painting and coating works are made aware of the permit conditions and that they comply with all specified safety requirements.

5.0 Procedure 5.1

General •

All personnel performing painting or coating work shall be trained for the work and be aware of the hazards of the particular materials & equipments being used. Also, the equipment shall be in good working order and all safety guards installed.

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No painting / coating work shall be carried-out without due authorization under appropriate Work Permit and must be carried out in a safe manner with full compliance to any applicable KOC Standards and HSEMS Procedures.

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Care shall be taken that painting activities at no time pose a threat to other persons in the area, who are not directly involved in the activity and the painting job in occupied areas should be avoided in official hours. Spray gun should not be pointed at anyone or part of the user's body.

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Strict attention to cleanliness shall be observed in all painting and coating operations. All debris, spilled paint / solvent , used or unwanted paint / solvents, used up cans / drums and used abrasives shall be collected and disposed of in accordance with KOC HSEMS Chemical Spill Cleanup Procedure (KOC.EV.005), Waste Management Procedure (KOC.EV.008) and Transport, Storage and Handling of Hazardous Material (KOC.EV.007).

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Areas where hazardous work is being carried out (such as abrasive blast cleaning and airless spraying) shall be suitably barricaded to keep personnel out of the

Control Tier: 3

Revision Date: May 25, 2009 Uncontrolled Copy. Valid Only at the Time of Printing: 10-Jun-09

Painting & Coating HSE Procedure Page 3 of 7

hazardous area, or the timing of the work shall be such that only the work crew doing the job is present at the site. Warning signs shall be posted in hazardous areas with suitable warnings of the potential dangers (i.e.,“ No entry, Spray painting in progress etc."). •

Foodstuffs shall not be brought into or consumed on premises where paint is stored, handled or used and also the utensils or receptacles which could be used for the storage or consumption of food or drink shall not be permitted.

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Wash the face, hand & arms thoroughly after each painting session. Solvents shall not be used for cleansing the skin. Special skin cleansers shall be provided by the contractor together with skin creams to prevent excessive drying.

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Dedicated painting booths shall be provided in facilities where painting is regularly performed. They shall be designed such that any vapour, mist or overspray is contained within the booth, and presents no hazard to persons working outside. Wherever painting cannot be done at paint booth, the ground should be covered to avoid spillage of paint causing soil and drain (water) contamination.

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Painting booths shall be of fire-resistant construction, and subject to rigorous cleaning to prevent the build-up of solid paint residues.

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Painting booths shall conform to the guidance laid down within ‘NFPA 33 Standard for Spray Application Using Flammable & Combustible Materials'.

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Painting booths shall be supplied with adequate ventilation, both fresh air supply and contaminated air extraction, for the elimination of vapours, mists and airborne particles, such that the concentration of flammable vapours in the air is maintained in a safe level in terms of LELs.

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Extraction fans shall be ducted to exhaust safely, away from ignition hazards, and occupied working areas. They shall be fitted with filters such that the exhaust poses no threat to personnel or the environment.

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All paint spraying devices shall be electrically bonded to the item being sprayed and metal to metal contact must be ensured while bonding.

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All electrical fittings, lighting and appliances within the booth shall conform to the requirements in KOC standard for Hazardous Area Classification (KOC-G-002) and KOC Recommended Practice for Selection, Installation and Maintenance of Electrical Equipment in Hazardous Areas (KOC-E-004)."

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The spray painting operation should be conducted from the upwind side of the object being coated, wherever practicable.

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Before using airless spray equipment, all guards recommended by the manufacturer shall be in place and the system shall be in good order and correctly grounded to prevent static build-up.

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Personnel involved with using paints and solvents shall be in good health and have periodic medical examinations / biological monitoring (specific to exposed chemicals) by professional medical staff.

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MSDS of the paint should be made readily available at the work site for handling emergencies effectively.

Control Tier: 3

Revision Date: May 25, 2009 Uncontrolled Copy. Valid Only at the Time of Printing: 10-Jun-09

Painting & Coating HSE Procedure Page 4 of 7

•

Gas test should be carried out before and after painting works to ensure that area is not in flammable range.

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Necessary precautions such as utilizing approved scaffolding / use of full body harness/ use of equipment for working at heights / barricading the area underneath the painting area etc. should be followed while performing painting works at heights.

5.1.1

Ventilation / Painting inside Confined Spaces

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Ventilation is a necessity when painting in confined areas because solvents tend to be heavier than air and migrate to lower levels. The fresh air inlet of the ventilation system should be located near the top of the confined space, and the discharge should be located near the bottom, positioned to eliminate dead air spaces. Supplementary fans may be necessary to ensure good air circulation.

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Natural ventilation through open man ways, etc. is rarely sufficient to keep local vapor concentrations to a safe level in terms of PELs or LELs. As a general rule, forced ventilation shall be used, especially in small enclosures and always during spray painting.

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There should be minimum two persons to work in Confined spaces.

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Air supplied respirator should be provided when workers are continuously exposed in spray painting inside a confined space.

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Hot work shall not be permitted inside the confined space during painting works.

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Ensure that all the electrical equipment used including the ventilation equipment are grounded properly.

Refer to KOC HSEMS Procedure on ‘Entry into Confined Spaces’KOC.SA.007 for more details on confined space work requirements. 5.2

Surface Preparation

Equipment and materials that are used in surface preparation for paints and coatings can be hazardous if used carelessly. Waste generated on account of surface preparation shall be disposed as hazardous or non-hazardous waste depending on the contents. There are several methods for preparing surfaces and these include: •

Blast cleaning where abrasives in the form of grit, slag, etc. are used. Other types of blast cleaning use high pressure water or steam.

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Hand or power tool cleaning includes grinders, sanders, rotary wire brushes, impact tools, chisels, hammers.

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Chemical cleaning using paint removers, or solvents, alkali, acids or detergents.

Refer to HSEMS Procedure on ‘High Pressure Water Jetting, Abrasive Blast Cleaning and Steam Cleaning’ (KOC.SA.011) for more details.

Control Tier: 3

Revision Date: May 25, 2009 Uncontrolled Copy. Valid Only at the Time of Printing: 10-Jun-09

Painting & Coating HSE Procedure Page 5 of 7

5.2.1

Fire Precautions

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All potential sources of ignition shall be kept away from areas where flammable paints, coatings and their associated solvents are stored, handled or used and hot work should not be permitted at elevation of painting works.

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All electrical lighting, wiring and equipment shall be explosion-proof and must be suitable as per hazardous area classification (class I, division I or class II, division 1).

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All electrical equipment such as switches, panel boards, electrical motors and associated equipment must be de-energized before spray painting to eliminate explosion hazards.

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Solvents and solvent based paints shall not be applied to surfaces exceeding Kuwait summer ambient temperatures and solvent spray painting shall not be done on hot surfaces / tanks, pipelines and vessels/containers.

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Fire extinguishers should be provided at the work area or storage facility for painting materials and the workers should be trained on the use of fire extinguisher in case of fire.

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Ensure that adequate ventilation is provided in all areas where paints, coatings and associated solvents are stored, handled or used, in order to prevent the buildup of vapors to above the LEL (Lower Explosive Limit).

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Unknown chemicals should not be added to paint to avoid fire by mixing incompatible agents (oxidizing agents).

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Extension cords or other electrical plug-in cords should not be used in a spray paint booth.

5.3

Storage of Paints / Solvents •

Provide specific stores for paints, coatings and their associated solvents and it should be situated in a safe area, away from active work areas (daily consumption store and bulk storage shall be separated). Where ever possible paint storage shall be located on a permanently supervised site and outside the battery limits of operational areas.

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Stores shall be of a fire resistant construction and shall conform to the guidance for handling and storage as laid down in NFPA 30.

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The store shall be ventilated to prevent a build-up of temperature within the store.

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Open containers of paint, or other substances shall not be stored in paint stores. Partially used containers of paint or thinners remaining unused at the end of the day shall be resealed, cleaned and returned to the store.

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Dispensing or decanting of material from one container to another shall not take place within the store but shall be in the open air away from hazardous areas of operation.

Control Tier: 3

Revision Date: May 25, 2009 Uncontrolled Copy. Valid Only at the Time of Printing: 10-Jun-09

Painting & Coating HSE Procedure Page 6 of 7

5.4

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The contractor shall display, `No Smoking' and `Flammable' safety signs prominently in all areas where flammable paints, coatings and associated solvents are stored.

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All potential sources of ignition shall be kept away from areas where flammable paints, coatings and their associated solvents are stored or handled.

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The receptacles containing lead based paint must be legibly marked to alert about lead hazard. Personal Protective Equipment (PPE) requirements for Painting work

Personal protective equipment is required for the majority of operations that involve coating or paint application. The amount and type of personal protection depends on the work being carried out and the location. Table 1.0 gives a summary of essential personal protective equipment that must be worn by personnel carrying out specific duties. Table 1.0 - PPE Selection Criteria: Painting Method

Product

Respirator

Latex paints

Brush

Oil-based products Products containing isocyanates

Latex paints

Roller

Oil-based products Products containing isocyanates Latex paints

Spray System

Oil-based products Products containing isocyanates

Control Tier: 3

Not required in wellventilated areas Airpurifying half mask Airsupplied full face Not required in wellventilated areas Airpurifying half mask Airsupplied full face Airpurifying half mask Airpurifying full or half mask Airsupplied full face

Respirator Cartridge

Gloves

Eye Protection

Hearing Protection

Protective Clothing

N/A

N/A

N/A

Depends on noise sources

Coveralls

Organic vapour

Nitrile

Safety glasses

N/A

Nitrile

N/A

N/A

N/A

N/A

Organic vapour

Nitrile

Safety glasses

N/A

Nitrile

N/A

Nitrile

Safety glasses or goggles

Yes

High-density polyethylene suit

Nitrile

Goggles (if using a half mask respirator)

Yes

High-density polyethylene suit

Nitrile

N/A

Yes

High-density polyethylene suit

Organic vapour with particulate filter Organic vapour with particulate filter N/A

Depends on noise sources Depends on noise sources Depends on noise sources Depends on noise sources Depends on noise sources

Coveralls High-density polyethylene suit

Coveralls

Coveralls High-density polyethylene suit

Revision Date: May 25, 2009 Uncontrolled Copy. Valid Only at the Time of Printing: 10-Jun-09

Painting & Coating HSE Procedure Page 7 of 7

Site supervision to ensure that, all personnel involved in painting / coating works are provided with required PPE’s such as eye & face protection , respiratory & body protection and any other PPE as per the specific instructions / MSDS given by the paint manufacturer. The following should be followed to ensure proper usage of PPE: •

Ensure that If a respirator is used , it is fit tested first and thereafter the fit test must be repeated at least annually to ensure that face seal remains effective.

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Ensure that the air supplied to the air fed respirator/visor is clean and filters in the air supply system are checked regularly.

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Wear clean and disposable overalls, gloves and face/eye protection when mixing paint or brush/roller/spray painting to prevent splashing onto your skin.

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Do not keep respirators, visors, gloves or overalls in the spray paint booth/area. Do store them in a locker/clean area and check that they are in order before use.

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Do not use air-purifying respirators when working in an oxygen deficient environment.

6.0 Key Documents/Tools/References • • • • • • • •

Fire & Safety Regulations:-Chapter 13.3 HSEMS Procedure on ‘Permit to Work’ (KOC.SA.004) HSEMS Procedure on ‘Entry into Confined Spaces’(KOC.SA.007) HSEMS Procedure on ‘High Pressure Water Jetting, Abrasive Blast Cleaning and Steam Cleaning’ (KOC.SA.011) KOC Standard for Personal Protective Equipment ( KOC-L-010 Part1 ) KOC Standards for Painting and Coating(KOC-P-001 to KOC-P-005) KOC Recommended Practice for Selection, Installation and Maintenance of Electrical Equipment in Hazardous Areas: Part 1 to 6 NFPA 30 & 33

7.0 Abbreviations • • •

HSE – Health, Safety & Environment HSEMS – HSE Management System KOC – Kuwait Oil Company

Revision Log Revision Date

Document Approver Technical

Document author

April 26, 2009

Manager Ahmadi Services

TL Safety

May 25, 2009

Manager Ahmadi Services

TL Safety

Control Tier: 3

Revision Details

Draft procedure circulated among HSEMS Implementation Committee members for review Approved and issued for implementation by the HSEMS Implementation Committee

Revision Date: May 25, 2009 Uncontrolled Copy. Valid Only at the Time of Printing: 10-Jun-09