Blasting and Painting MODULE

HSE STANDARD

Module 32Blasting and Painting

THIS DOCUMENT CONTAINS ONEMODULE IN A SET COMPRISING

HSE STANDARDSFOR THE

BRUNEI SHELL COMPANIES

Revision

2.0

May 2000

Approved by: SCODocument Owner: HSE

IMPORTANT NOTICE

This module is one of a series produced by Brunei Shell Petroleum Company Sdn Bhd. Theyrepresent the minimum acceptable HSE standards for a wide range of operations that are carriedout by, and for, the Brunei Shell Companies (BSC). �Brunei Shell Companies� or �BSC� are expres-sions 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 ShellTankers Sdn Bhd (BST) collectively. BSC is not a legal entity. Each of the four companies has itsown separate legal identity and objectives. The Government of Brunei Darussalam and Shell (whichis also an expression of convenience) are shareholders in all four companies, whilst there is a thirdshareholder in BLNG, namely Mitsubishi Corporation.

THIS DOCUMENT

Comment and feedback from users of this module is encouraged, in order that the series may beupdated as appropriate to reflect current requirements.

& HSE Standards Master Index, Module 00, document number TMS0434 which is republishedat regular intervals.

This document is unregistered. Brunei Shell personnel should obtain copies in accordance withthe procedure in HSE Standards Master Index, Module 00, , Chapter 4. Contract personnel shouldobtain copies from the Contract Holder.

Within the Corporate Management System (CMS) documentation hierarchy, this document has thestatus of Standards and its Process Owner is Head of HSE.

DISCLAIMER

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

THE BRUNEI SHELL COMPANIES HSE StandardMay 2000

Module 32 - Blasting and Painting

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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


HSE Standard THE BRUNEI SHELL COMPANIESMay 2000 of 15

1. INTRODUCTION

The inter-related activities of blasting and painting are carried out extensively on virtually allBSC assets and are done to renew, restore and maintain the surface coatings which protectstructures, plant and equipment from corrosion and damage.

Blasting is done by entraining special abrasive in an airstream and directing that streamagainst the surface to be prepared, in the process removing existing coatings, corrosion andscale. Painting uses materials, often containing volatile solvents, pumped at high pressuresto apply coatings to surfaces prepared by blasting or by other means such as washing or wirebrushing. There are obvious hazards associated with both activities and they include thefollowing:

� 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 risksassociated with blasting and painting activities, and will ensure appropriate controls are inplace to properly manage known risks.

This standard covers all aspects of blasting and painting wherever it is carried out and followsthe 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, isseparately covered in Module 25 - High Pressure Water Jetting.

The Process Owner of this module is SCO (EPM, SES/3, LEN)



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2. REQUIREMENTS

2.1 Blasting and Painting Personnel

Only competent personnel employed by a company on contract to BSC shall normally carryout blasting and painting activities on behalf of BSC.

Before being employed to carry out these activities, personnel shall demonstrate their com-petence through successful completion of a Trade Test conducted under the supervision ofthe Contractor.

Blasting and painting personnel (hereafter referred to as painters) shall be trained to stand-ards approved by BSC and this training will be carried out at recognised training establish-ments.

Personnel employed by a company on contract to BSC shall meet the requirements for eachjob category as shown in Table 1.

Table 1 - Personnel Requirements

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2.1.2 Personnel Records

Personnel records of painters shall be maintained and kept up to date by the contractor andbe 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 andinspection certificates shall accompany all air receivers, blasting pots, pressure hoses andpaint 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 fromentrained water and oil and should not exceed a temperature of 110 degree C at air receiverinlets. Adequate separators and traps shall be provided in compressed air systems and theseshould be installed in the coolest parts of the systems. They shall be emptied regularly toprevent carryover and air receivers shall be periodically drained down.

Blasting hoses, whatever type of hose connector is used, shall either have their connectorsmechanically wired together or have secondary hose end retaining or locking devices fitted toretain the hose end in the event of primary connector failure. In addition, blasting pot bottomhose couplings shall be fitted with safety slip wires. The use of swivel-action locking clampsin any part of a hose assembly is not permitted. Lay patterns for hoses shall avoid tight radiusbends and kinking.

Paint hoses shall be hydrostatically pressure tested at periods not exceeding 3 months. Thetest pressure shall be 1.25 x maximum working pressure and a satisfactory test must showno significant pressure loss over a period of one minute. Hoses which show bulges or cracksshall be discarded. Test results shall be recorded and be available for inspection by BSC onrequest. Hoses shall be clearly marked with their pressure ratings.

Blasting guns shall be fitted with deadman shutoff triggers. When the hose carrying theabrasive and air stream to a blasting gun is longer than 60m, an automatic actuated shutoffdevice shall be installed at the blasting pot end of the hose. Defeating the deadman facility onblasting 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 suitableearth points. To prevent the buildup of static electricity and the possible discharge of aspark, 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) shallhave electrical continuity and shall be electrically bonded to the objects or structures beingblasted 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 confirmproper conductivity otherwise it shall be bonded with a separate earth wire. The paint sprayhose shall be a semi-conductive material and the electrical resistance across earth pointsshall not exceed 1 Mohm. Resistance tests shall be carried out at the start of work, at dailyintervals and each time a new connection is made. Test results shall be recorded and enteredin daily reports.

All equipment shall be kept clean, properly maintained and stored under cover when not inuse. Hoses should be coiled to prevent damage.

Daily, systematic inspection of all components in blasting and painting systems shall becarried out before putting the equipment into service.



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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 fromreinforced fabric.

All abrasive supplies shall be stored in designated storage areas which shall be capable ofsupporting the loadings applied by the total weight of abrasive in store. Where the total loadapplied may exceed the permissable loading, warning signs shall be erected and regular checkscarried out by supervisors to ensure an unacceptable build-up does not occur. Abrasivesupplies 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 liftingpoints on the bags. Personnel directly involved in lifting 2 tonne abrasive bags shall beproperly trained in appropriate rigging techniques. Bags and sacks shall be pyramid-stackedto prevent toppling and shall not block access ways.

Storage areas and the areas around blasting pots shall be kept clean and tidy with sweepingsof grit properly disposed of using empty sacks and bags.

Proper manual lifting techniques shall be used to prevent personal injury when moving sacksof abrasive.

2.3.2 Storage of Painting Materials

All painting materials including paint, solvents, thinners, additives and cleaners shall bestored in a non-enclosed area remote from sources of heat and combustion and protectedfrom direct sunlight. In areas where major painting projects are undertaken, materials stor-age shall be in a dedicated paint storage container fitted with explosion proof light fittingsand a fire extinguishing system. Portable fire extinguishers shall be kept in the immediatevicinity of paint containers and areas where significant amounts of painting materials arestored. Access to paint storage areas shall only be made in accordance with an entry proce-dure 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 legiblymarked with descriptions of the contents. This shall include the specification number, col-our reference number, method of application for which it is intended, batch number, date ofmanufacture, manufacturer's name, initials or recognised trade mark, and any specific stor-age instructions.

Materials Safety Data Sheets (MSDSs) or Safe Handling of Chemicals (SHOC) informationshall be available for all painting materials.

Materials shall be stored in accordance with manufacturers special instructions or proce-dures and any stipulations set out in MSDSs and SHOC cards. Incompatible volatile sub-stances shall be segregated.

Unidentified or expired painting materials shall neither be accepted into storage nor kept instore.

Proper manual lifting techniques shall be used to prevent personal injury when moving con-tainers 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 paintingmaterials.

When transferring solvent from a metal drum into another container, the drum shall be elec-trically 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 shallbe followed and any specific information from MSDSs or SHOC cards taken into account. Ifspecified or if necessary, appropriate personal protective equipment shall be supplied andworn in accordance with the relevant sections of HSE Standards Module 02 - Personal Pro-tective 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 outunder permit control and shall be in full conformance with the requirements of the permit towork 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 brush-ing and pressure paint spraying. For all other activities related to blasting and painting in aproduction area, Cold Work Permits shall be required.

Work permits are not required for blasting and painting in areas designated for that specificpurpose, 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 suchitems in the area of activity have been protected and the protection approved by the AssetHolder. 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



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Screens shall be placed to prevent abrasive and dust from abrasive blasting operations affect-ing nearby buildings, installations, roads, etc.

The Contractor shall ensure the protection of equipment. If adequate protection cannot beachieved, the area will be considered unsuitable for abrasive blasting operations and alterna-tive methods of surface preparation employed, e.g. needle guns, solvents, wire brushes andchipping hammers.

The requirements for protection shall also apply during painting and the Contractor shallensure equipment protection against paint splashes and overspray. Wherever possible, spraypainting shall be carried out at a safe distance from other occupied areas, buildings andcarparks. Worksites shall be barriered off and warning signs placed at boundary limits.

Firefighting capability shall be provided e.g. portable fire extinguishers dry chemical typeplaced 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, onlystructures certified by a scaffolding company on contract to BSC shall be used. The Contrac-tor shall ensure that an accurate requirement for scaffolding is identified in advance of itbeing needed. The intended use and loadings will require to be clearly specified (refer to HSEStandard Module 06 - Scaffolding and Access).

Before start of work each day, Painting Supervisors shall check that the green faces of theSCAFFTAGs on scaffold structures are showing and that the weekly scaffold inspection recordis 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 ofspent grit.

� temporary lighting, if required, is suitable for flammable atmospheres and is working prop-erly.

� 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 beobtained 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 immediatevicinity of the activity and operators must be provided with and use appropriate protectionagainst these hazards.

In addition to the personal protective equipment requirements for boots, coverall, upper bodyprotection and gauntlets, protection shall be given by the use of air-fed helmets with a con-stant supply of breathing quality air. The addition of an air cooler to maintain the air supplywithin an acceptable temperature range is strongly recommended. Also recommended is theuse of visor outer surface 'tear-offs' in acetate or similar material to enable operators to main-tain full visibility.

Painting

The action of spray painting produces airborne paint particles in the form of a mist which cancause irritation to the eyes, nose, throat and lungs and may possibly lead to more severehealth problems.

As well as the basic personal protective equipment requirements referred to previously, pro-tection 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 StandardsModule 7 - Confined Spaces. In addition to these requirements, the following points shall beobserved:

� Ventilation of confined spaces must be sufficient to ensure all parts of the work site areadequately ventilated. Particular attention must be paid to tank and vessel bottoms whereheavier-than-air vapours may accumulate.

� Paint solvents have different characteristics to hydrocarbon gases. Since gas test metersare calibrated to methane,readings taken in an atmosphere contaminated by the baseconstituent of the paint solvent in use, e.g. toluene, xylene, must be subject to an appro-priate 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 siteprovided a separate test is carried out with a certificate issued prior to entry and theirexposure 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 usetime of solvent absorbent filters must be available on site.



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� 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 totaluse time has expired.

� When solvents are being used, Self Contained Breathing Apparatus Escape Sets (10 minutetype) must be kept immediately available just outside the confined space.

� Sufficient pneumatic lighting must be provided to ensure clear access way for blasters andpainters 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 thepolicy and procedures for Concurrent Production and Painting Activities (CPPA), documentreference TMS0569.

Work on live systems onshore happens regularly and is controlled through application of thePermit 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 facil-ity or when the wind direction is unfavourable.

� the state of corrosion of the facility does not present a significant danger. Recent NDTinspection reports may provide valuable information which can be used to help decidewhether 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 blast-ing, power cleaning or painting is carried out. After permission to carry out these activitieshas been given, the Asset Holder shall have the responsibility to ensure the continuingsafe condition of the facility.

2.4.7 Health and Hygiene

The information provided on MSDSs and SHOC cards is designed to protect the health ofpersons working with the substances and shall always be observed.

If paint spray is inhaled, penetrates the skin or enters the eyes, medical attention must beobtained immediately. Also, any unusual effects experienced during painting such as dizzi-ness, nausea or a burning sensation in the eyes shall be reported to a Painting Supervisorimmediately and medical attention obtained.

In all cases of medical attention being needed, an Incident Report (Omnisafe) shall be raisedin accordance with HSE Standards Module 30 - Incident Classification and Reporting, Mod-ule 31 - Incident Investigation Procedures.

Where there is a risk of solvent splashes on the skin, wash it down thoroughly with runningwater and barrier creams should be applied and gloves worn. The use of thinners, solvents orsimilar substances for removing paint from the skin is prohibited and wherever possible,proprietary skin cleansers should be used.



� Maintain good housekeeping on platform and vessel at all time.

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. Neverexceed the Safe Working Pressure of the equipment.

� Conduct compressor air supply breathing air tests for carbon monoxide, carbon dioxideand 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 beforedisconnecting 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 itoccurs and dispose of cleaning material correctly.

� At offshore locations, establish and maintain radio communication between the barge orwork boat and the Painting Supervisor on the platform.

� Maintain good housekeeping on platform and vessel at all time.



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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 re-ceived adequate information, instruction and training, and meet the requirements set outin 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 priorpaint 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 andstandard 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 documentedrecorded.



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Appendix 2 - Correction Factors for Pellistors in Gas Test Meters

To obtain an approximate LEL value for the gases/vapours below, multiply the meter reading on amethane calibrated detector by the value shown.

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DOCUMENT CHANGE PROPOSAL FORMThis 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 Revision No: Dated:

Document Owner: Name:

Please consider the following issue(s) for the next edition: 1

Reason for Change Proposal (Please mark the appropriate box) Urgency

Typographical error Technically incorrect Cheaper Urgent

Omission More appropriate Other Routine

From:Name: ..................................................................... Date: ..............................

Contact address/ind: .............................................. Phone: ...........................

Response: The change proposal is

Accepted Rejected because: Requires further work:

Form Owner: HSE Revision: 2.0 Dated: May 2000

Blasting and Painting MODULE

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