4.6.1 INTRODUCTION
Some of the materials encountered in work processes may involve exposure of personnel to potential short term or long term health effects.
Synthetic Mineral Fibres (SMF) are found as fibrous insulating material in the industry as a substitute for asbestos.
Chemical cleaning procedures pose special risks and require a knowledge of the preventive measures required to reduce contact hazards to a safe level.
Doc. Number Prepared By HSED Approved By
Network Loc. Directory Name HSE MANUAL Page No Page 159 of 448
4.6.2 SYNTHETIC MINERAL FIBRES
Many asbestos substitutes are based on SMF of various types such as glass fibre, rock wool, slag wool and refractory ceramic fibres. These are found in many applications within ADGAS, mainly in tapes, lagging, gaskets and other insulating applications.
In general, SMF are less hazardous than asbestos, but there is still some potential for harm if dust is produced during handling. Safe handling of SMF products therefore, requires precautions that are similar to those used for asbestos, although less stringent.
SMF Handling Procedure
General safety requirements in the handling and use of SMF include:
· Selection of those products packaged and/or treated to reduce the generation of dust.
· Procurement of the material pre-cut as far as practicable to reduce on-site work.
· The use of manually operated tools for on-site cutting or shaping.
· Ensuring that the material is clearly labelled with the product identification and contents, directions for use and precautions.
Note
Special protective procedures will be required only if the SMF is likely be disturbed and if significant amounts of free fibre may be generated. For larger long term work, preparation of a Task Risk Assessment and a work permit are required.
Large scale disturbance or working of SMF involving exposure to fibrous dust requires the operators to:
· Wear an appropriate particle respirator, dust goggles, gloves and one piece hooded disposable overalls.
· Damp or wet down materials wherever possible
· Clean up Synthetic Mineral Fibre (SMF) waste immediately. If dust is present, use vacuum or wet methods.
· Securely package or label surplus SMF for future storage and use if required.
· Package and label waste SMF to be disposed of according to the environmental procedures.
4.6.3 ASBESTOS
Company policy is to avoid the use of asbestos wherever possible. There are some applications however, where non asbestos substitutes are less than satisfactory or unsafe and white asbestos may still be found in the form of:
· CAF gaskets (compressed asbestos fibre)
Doc. Number Prepared By HSED Approved By
Network Loc. Directory Name HSE MANUAL Page No Page 160 of 448
· SWAF gaskets (spiral wound asbestos fibre)
· Asbestos based packings for valves and pumps.
· Asbestos woven tape for high pressure vessels (boiler steam drum).
· Some brake linings
· Boiler FD air dust bellows.
Because of crystalline structure, asbestos splits to produce fine fibres which can remain suspended in the air for considerable periods. When inhaled, fine asbestos fibres are capable of being deposited in the deepest regions of the lung, where they may cause diseases such as asbestosis and mesothelioma, both forms of lung cancer.
To control exposure of airborne asbestos fibres, whenever work with asbestos is
conducted, practicable measures wherever applicable should be undertaken as follows:-
· Adherence to working methods which minimise breakage, abrasion, machining, cutting that might generate dust.
· Suppression of dust by keeping the material wet, where appropriate.
· Temporary segregation – avoid asbestos work and other activities in the same place.
· Keeping work areas clean by removing debris offcuts promptly.
· “Permit to Work” system.
The controlled wet stripping technique could be an effective method in minimising dust release.
Asbestos Handling Procedure
Procedures for Removal of CAF/ SWAF with Gaskets and Packing Material
Obtain the required replacements from the store. Ensure they are correctly packaged in polyethylene bags and labeled.
Prior to breaking the line flanges, ensure that any residual line pressure is vented away from the system. Loosen bolts of the flange or spade in the respective line.
Wear PVC/ Neoprene long sleeve gloves and disposable half face piece valved mask
“JSP make FFP3/SL”, NPF 50 prior to starting the job.
Do not use electric or air powered tools for removal of stuck gasket material.
Wet the gasket surface by spraying with water using the garden spray pot. Spread a polyethylene drop sheet underneath to collect all pieces dropped on floor.
Remove slowly the old gasket or packing, place it directly into a specific “Asbestos disposal bag” with “Asbestos Warning Label”. Seal the bag and place it directly into the
Doc. Number Prepared By HSED Approved By
Network Loc. Directory Name HSE MANUAL Page No Page 161 of 448
dedicated “Asbestos only container”. Avoid breaking the gasket and packing material into small pieces.
If all or part of the gasket sticks to the face, wet it with water. Manually scrape and wire brush the remnants. Re-wet as often as necessary to prevent dust formation.
Fold the drop sheet and dispose it in the “Asbestos Disposal Bag”.
Wash hands and face with soap and water thoroughly to remove any residual contamination.
Maintenance Procedure with asbestos lagging and Other Asbestos Reinforced Calcium Silicate Insulation (Friable Asbestos)
Contractor employees engaged in asbestos related work must be assessed for
competency by ADGAS Job Officer, in safe handling, working and disposal of asbestos containing material, according to this procedure.
Wear disposable zipped up boiler suit and disposable half face piece valved mask “JSP make FFP3/SL”, NPF 50.
Put tools and wet cleaning rag and water spray inside plastic glove bag for asbestos. In absence of plastic glove bag, use disposable gloves.
Sprinkle water using the garden spray pot on the surface of the insulation.
Areas where insulation is required to be removed wrap the plastic glove bag around the area of the pipe and seal it with masking tape.
Put a plastic drop sheet underneath the area where the insulation will be removed.
While removing the insulation sprinkle water intermittently to keep the surface always wet and avoid dispersing of the friable fibers.
Once all insulation removed and collected in glove bag, clean the pipe surface with wet rag to remove any remnant particles/ fibers from the surface; and then gradually remove glove bag from the pipe.
Fold and dispose the “Asbestos glove bags” in the “Asbestos Disposal Bag”. Seal the bag and place it directly into the dedicated “Asbestos only container”.
Doc. Number Prepared By HSED Approved By
Network Loc. Directory Name HSE MANUAL Page No Page 162 of 448
Note
Where insulation dismantling work is more than the area covered by glove bag, use a plastic sheet underneath and wet area thoroughly and use trolley
mounted full mask breathing apparatus. Area must be barricade at least 5 meter around job to minimize exposure of other personnel working in the area, and displayed with standardized warning sign.
Do not use electric or air powered tools for removal of insulation material.
During tea and lunch breaks, remove used PPE and dispose inside the “Asbestos Disposal Bag”. Always remove the disposable coverall first and then remove the half piece face mask.
Wash hands and face with soap and water thoroughly to remove any residual contamination.
4.6.4 QMB AND CWS AREAS
Cutting and finishing CAF, SWAF and Asbestos packing material must be carried out in well ventilated and isolated area which should be permanently assigned for this job.
Instruction “Asbestos material-Keep Away’ should be displayed in the same area. Do not use electric or air powered tools.
Before the activity starts, the employee must wear a disposable zipped up boiler suit and disposable half face piece valved mask “JSP make FFP3/SL”, NPF 50. Put a plastic drop sheet in the area of gasket cutting/ packing material finishing.
After the activity is over wipe off the contaminated tools with moist cloth and discard it along with the remnants and the PPE outfit in the provided Asbestos disposal bag. Roll up plastic sheet and put if in the asbestos disposal bag. Tie the bag properly to avoid any spill. Always remove the disposable coverall first and then remove the half piece face mask.
Put the filled Asbestos only bag in the provided Asbestos container in the respective areas. No other waste to be dumped in the asbestos only container. Seal the container once it is full.
Wash thoroughly face, hands and other exposed parts of the body with soap and water.
A waste disposal form must be filled and authorized by HSED prior to disposal from the area.
Doc. Number Prepared By HSED Approved By
Network Loc. Directory Name HSE MANUAL Page No Page 163 of 448
4.6.5 ASBESTOS WASTE DISPOSAL
The containers having asbestos waste shall be stored in a secure barricaded area. An instruction board “Asbestos Material Keep Away” should be displayed in Arabic, English, Hindi, Urdu & Malayalam.
The quantity of asbestos waste shall be recorded by the concerned supervisor.
When the asbestos containers are full, they should be properly sealed.
A Waste Disposal Form must be filled by the responsible supervisor and authorised by HSED prior to dispatch of the containers to Ruwais for disposal.
Note
In case the half-valved face piece mask is out of stock in the store, the person engaged in Asbestos Handling Materials must wear a disposable dust mask.
Wear personal protective clothing as specified by the perceived risk of contamination and inhalation in the job.
Note
Bags for asbestos waste must be of double wall heavy duty plastic with legible asbestos warning labels.
4.6.6 LAGGING AND OTHER FIBROUS INSULATION
The removal or installation of large quantities of lagging or insulation containing asbestos or SMF fibres must be performed by a contractor familiar with this type of work.
Removal and replacement of lagging and cladding from valves, flanges and small items of equipment, will require the following precautions:
· Wear disposable overalls and an appropriate respirator.
· Use a plastic drop sheet to catch loose material. Fold and dispose of it according to current regulations.
· Maintain the material in a wet condition during the work if possible.
4.6.7 STORES PROCEDURES
The day to day management of stock items of gaskets and packings involves the following precautions and procedures:
· All bins and racks containing asbestos items must be clearly labelled with black letters on a pink background (the colour pink identifies asbestos materials within ADGAS)
Doc. Number Prepared By HSED Approved By
Network Loc. Directory Name HSE MANUAL Page No Page 164 of 448
· SWAF and CAF gaskets are stored in labelled plastic bags in the prescribed height in the rack
· Asbestos packings in the storage bins must be in the required labelled plastic bags.
· Handling asbestos items is kept to a minimum and issue of gaskets is in multiples of 3, 5 or 10 depending on size
· Any opening of sealed bags must be performed so that dust is contained in the bag.
No specific personal protective wear is required for these routine activities in the store.
Major movements of the store asbestos inventory or major housekeeping activities will require the use of full personal protective wear and isolation of the area with signs and barriers.
All waste in sealed, labelled plastic bags is to be disposed of in the prescribed manner.
4.6.8 CHEMICAL CLEANING 4.6.8.1 INTRODUCTION
Cleaning methods that may involve the use of chemicals are:
· Removal of scale produced by corrosion on metal surfaces
· Removal of by-products from process systems
· Removal of inorganic salts from water heat transfer surfaces
· Removal of oil and grease from mechanical equipment
· Rust conversion
Chemical agents used are normally acid or alkaline solutions containing corrosion
inhibitors, or they may be organic solvents. As these chemicals may be used at elevated temperatures, additional hazards may be associated with their use.
Risks associated with the use of chemicals and solvents for cleaning purposes include:
· Eye and skin injuries as a result of contact with the cleaning agent.
· Health effects of the respiratory system due to the inhalation of chemical agents.
· Narcosis (dizziness) from inhalation of solvent fumes which may result in lack of control in work tasks and risk of disease.
· Metal corrosion leading to the weakening of associated equipment that can arise from the wrong choice of cleaning agents, inadequate inhibition of cleaning solutions or use of excessive temperatures.
· Generation of flammable and/or toxic gases that may arise from the chemical process or the reactions involved.
· Environmental pollution as a result of spilt or incorrect disposal of cleaning agents.
Chemical cleaning of large items of fixed equipment may involve the problems of:
Doc. Number Prepared By HSED Approved By
Network Loc. Directory Name HSE MANUAL Page No Page 165 of 448
· Damage to associated equipment.
· Spillage and run-off causing environmental pollution.
4.6.8.2 WORK PERMITS
For chemical cleaning with hazardous agents, the use of high pressure, or risk to plant and personnel, a work permit is required detailing all safety requirements and
procedures. Use of flammable chemicals is to be avoided with substitution by water soluble agents wherever possible. Any flammable vapours produced by cleaning must be treated in the same way as other flammable emissions on the plant.
Work permits must specify all personal protective wear according to the risk. Reference to the MSDS for the cleaning agent and process will suggest the correct type to wear which may include as required:
· Breathing mask or other respiratory protection
· Face shield and chemical goggles
· Chemical resistant gloves
· Chemical work suit, apron or appropriate barrier
· Chemical resistant safety approved footwear
· Standard safety helmet if compatible with other headgear Note
The appropriate use of the above safety wear will be determined using a Task Risk Assessment with the MSDS as a guide.
Included in the safety precautions are the provision of emergency shower and eye wash facilities and agreed emergency procedures.
4.6.8.3 CHEMICAL AGENTS AND EQUIPMENT
Chemical containers must be safely transported, segregated, stored and used
accordance with the MSDS. Containers must be labelled according to the nature of the chemical under the chemicals regulations.
All pumping and dispensing equipment must be inspected and maintained in serviceable condition. Quick release fittings shall be secured with safety clips and all necessary steps taken to avoid over pressuring systems.
Doc. Number Prepared By HSED Approved By
Network Loc. Directory Name HSE MANUAL Page No Page 166 of 448