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Sop 905

This document establishes safety requirements for abrasive blasting operations. It defines key terms, lists approved abrasive agents, and outlines procedures to increase safety. The procedures require blasting to occur in designated areas when possible, and for additional precautions like barriers and permits when blasting outside these areas or on storage tanks. Personnel must be trained according to the document and its safety requirements.

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0% found this document useful (0 votes)
299 views10 pages

Sop 905

This document establishes safety requirements for abrasive blasting operations. It defines key terms, lists approved abrasive agents, and outlines procedures to increase safety. The procedures require blasting to occur in designated areas when possible, and for additional precautions like barriers and permits when blasting outside these areas or on storage tanks. Personnel must be trained according to the document and its safety requirements.

Uploaded by

harry
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Abrasive Blasting SOP- 905

Safety Operating Procedure


Beaumont Refinery

Abrasive Blasting

Approval:_______________________
SHE Manager

Owner: Field Safety

Supports OIMS: 5-1 Endorsed:______________________


Chairman JH&SC

Scope This SOP establishes minimum requirements to ensure safe abrasive


blasting operations. The Abrasive Blasting SOP applies to ExxonMobil
employees and contractor personnel and must be used in conjunction
with other established guidelines such as SOP - 902 Hot Work Permits,
SOP -701 Equipment Isolation, SOP-309 Lead Control and SOP - 306
Respiratory Protection where applicable. There are also additional
requirements used to establish minimum requirements for abrasive
blasting for storage tanks.

Objectives Increase employee awareness and understanding of the Abrasive


Blasting SOP.

Aid in the preparation of storage tanks for the issuance of a Hot Work
Permit.

Establish minimum requirements to ensure safe abrasive blasting


operations, including the selection of abrasive blasting agents.

Provide guidance in the selection of respiratory and other PPE.


Increase awareness of procedures for personnel performing,
assisting, or working within 50 feet of abrasive blasting.

Provide training requirements associated with abrasive blasting


operations for Mechanical Supervisors/ExxonMobil Representatives,
blasters, kinkers, and other affected personnel.

Primary Users Safety


with Mechanical
Responsibilities
Process
Technical
Contractors
OIMS Administrator

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Abrasive Blasting SOP- 905

Definitions Abrasive Blasting Hood - Currently, only Clemsco Style Apollo 16


Abrasive Blasting Hoods are approved for ExxonMobil personnel.
This is a special type of loose-fitted covering with the hood material
designed to withstand abrasive material with impact resistant viewing
lens.

Auxiliary Personnel - Any individual within a 50-foot radius of an


abrasive blasting operation.

Blaster - The individual operating the abrasive cleaning equipment.

Designated Area - An area of the refinery specifically designated for


abrasive blasting operations, the Central Abrasive Blasting Area
(South of FCC Unit). Work conducted outside of a designated work
area will require at a minimum at least two personnel, a blaster and
kinker. However, a designated area allows for a variance from the
outlined procedure. A blaster may work by him/herself in this area,
provided that he/she has radio communication and that all other
requirements of this procedure are fully met.

Kinker - Any individual designated to oversee the proper functioning


of the air filtration/monitoring system supplying breathing air to the
blaster. The kinker may perform additional duties as necessitated by
the job.

Low Silica - Abrasive cleaning agents containing less than or equal to


one (1) percent free silica.
Those approved abrasive cleaning agents include:
Black Beauty
Black Magic
Blastite BT
Garnet
Green Diamond
Miracle Blast
Sure Shot
Alternative agents must be submitted to the Industrial Hygiene
group for written approval.

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Abrasive Blasting SOP- 905

Definitions, cont. Non-silica Abrasive, cleaning agents containing no free silica.


Those currently being used in the yard include:
Baking Soda
Dry Ice
Walnut Shells
Depending upon the non-silica abrasive cleaning agent being used
(baking soda or walnut shells) and the composition of the surface
coating to be blasted, the blaster may not be required to wear a
supplied air respirator. Consult Industrial Hygiene for guidance if a
variance from the respiratory equipment as outlined in this procedure is
desired.

Portable Lifeline Air Filtering System - Air filter currently approved


for ExxonMobil personnel is the portable Industrial Scientific Air
Filtering System, Model PL-100, which has an integral carbon
monoxide monitor, digital display and an audible alarm.

Shielding - Barrier which provides protection for Kinker and auxiliary


personnel from dust resulting from abrasive blasting. Industrial
Hygiene, following notification by the Mechanical Supervisor of the
composition of the surface coatings, will determine if shielding is
necessary and will additionally provide guidance as to the type and
size of barrier needed on a case-by-case basis.

References API 2027: Ignition Hazards Involved in Abrasive Blasting of


Atmospheric Storage Tanks in Hydrocarbon Service

SOP 401 Fall Protection Systems, Scaffolds, and Aerial Lifts

SOP 701 Equipment Isolation (Lockout/Tagout)

SOP - 306 Respiratory Protection

SOP - 902 Hot Work Permits

Documentation The affected departments must document that training of their


and Records respective personnel is accomplished and kept up-to-date. This
certification must contain each employee's name, social security
number and date of training. This information is to be input into the
TERMS system. Additionally, the ExxonMobil Representative should
forward all training documentation of contractors to the Contractor
Safety Administrator.

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Abrasive Blasting SOP- 905

Procedure
Abrasive Blasting 1. Whenever possible, blasting should be done in a designated area.
Area Procedure If feasible, equipment and materials that can be transported should
be abrasive blasted in a designated area prior to installation.
2. Blasting areas must be kept free of dust/grit buildup. This will
require a frequent cleaning of the work area, to include preventing
the accumulation of dust outside the blasting area.
3. When blasting is performed outside of a designated area (e.g., in
pipe right-of-ways, within the battery limits of a process unit,
storage tanks), additional preparation of the area will be required.
This includes but is not limited to marking the area with warning
signs, covering sewer drains, covering air intakes and protecting
instrumentation, and obtaining a hot work permit. Special
precautions for abrasive blasting of storage tanks are
addressed in "Additional Requirements" section of this SOP.
4. When blasting is required outside of the designated abrasive
blasting areas, access barriers such as warning signs and/or red
traffic cones (and road blocks if needed) shall be placed on a 50-
foot radius of the blasting area.
5. Additionally, shielding, as determined by Industrial Hygiene, may
be necessary to reduce potential exposure of dust to auxiliary
personnel.

Blaster Use of 1. The wearing of respiratory protective equipment is mandatory while


Respiratory in the 50-foot radius of the blasting area. Minimum respiratory
Protective protective equipment for the blaster must include:
Equipment a. Air supplied respiratory protective equipment with current
NIOSH approval for blasting.
b. Helmet, or full face-piece with hood, and provide protection for
head, neck, and upper body from rebounding abrasive.
c. Note: Respiratory protective equipment for blasting is designed
for use only in atmospheres not immediately dangerous to life
or health. It is not a substitute for self-contained breathing
apparatus or airline breathing apparatus.

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Abrasive Blasting SOP- 905

Blaster Use of 2. Respiratory protective equipment (including air hoses) should be in


Respiratory good physical condition with only manufacturer-approved
Protective modifications. The hose used from the air source to the hood
Equipment, cont. should be flexible and long enough to prevent placing any undue
stress on it. It must be connected to the air control valve on the
body belt. All hose connections for breathing air for both
ExxonMobil and contractor personnel must use Hansen fittings. No
adapters or other connectors shall be used for this application.
a. Respirators (Reference SOP-306 Respiratory Protection)
b. Gloves
c. HEPA Vacuum
3. The air source must provide a reliable supply of clean, breathable
air. Breathing air may be supplied from one of two sources:
a. A compressor with filtration and monitoring equipment (e.g.,
Industrial Scientific Air Filtering System with carbon monoxide
monitor designed to produce, sustain, and ensure Class D
quality breathing air. Calibration of the air filtering system must
be current (within 30 days of start date). The compressor shall
be constructed such that entry of contaminated air into the
system is avoided. The air inlet should be located at least 3
feet above grade level, and well separated from the exhaust if
an engine driven compressor is used. A designated kinker will
monitor the warning alarm system and the air compressor.
b. A breathing air cylinder cascade system with a pressure
regulator to control the pressure to the operator's hood
according to the manufacturer's specifications.
Note: There are no permanently fixed breathing air systems in the
refinery. Documentation of breathing air quality is required prior to use.
Yard air and instrument air are unfit for use as breathing air.

Kinker & Auxiliary 1. The kinker and auxiliary personnel exposed to dust must use air-
Personnel Use of purifying respirators: half face-piece with High Efficiency
Respiratory Particulate/Aerosol (HEPA) cartridges.
Equipment a. Complete, all PPE and tools shall be rinsed clean or HEPA
vacuumed of MMMF, then removed and stored for later use or
disposed of with the waste MMMF.
b. Good personal hygiene should be practiced at the end of any
task handling MMMF material.

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Abrasive Blasting SOP- 905

Use of Personal 1. Heavy canvas or leather gloves shall be worn during blasting
Protective operations by the blaster. Additional personal protective
Equipment equipment, such as fall protection, may be required, depending on
the location of the work (refer to SOP 401 Fall Protection
Systems, Scaffolds, and Aerial Lifts).
a. The blaster, kinker, and auxiliary personnel within the
designated or marked areas shall wear appropriate clothing
(Nomex), hearing, eye, and head protection.
b. The coveralls or other clothing worn by the blaster must provide
sufficient protection from deflected materials.

Use of Mechanical 1. Blasting equipment shall include a hopper, a compressor, and a


Equipment blasting hose with a nozzle. The nozzle must be equipped with an
operating valve which must be held open manually and which will
immediately shut off the flow of abrasive material automatically
upon release of the handle by the operator (deadman valve).
2. All hose lines must be in good condition and all hose connections
secure.
3. The piping, joints and valves on the blasting machine and pressure
pot must be in good condition - no leaks.

Training and 1. Following initial implementation and training for these guidelines,
Communication Maintenance and other applicable departments will provide
retraining for their Mechanical Supervisors, ExxonMobil
Representatives, blasters, kinkers, and other affected personnel
every two years and:

a. Whenever there is a change in personnel job assignments


b. A change in equipment,
c. When there is a change in the abrasive blasting guidelines.
2. Retraining will also be conducted if results of periodic inspections
reveal inappropriate deviations from established abrasive blasting
requirements.

3. The retraining must include the following:

a. For kinkers, working knowledge of the air compressor,


breathing air filtration system and warning alarms, and
emergency first response.
b. For blasters, recognition of exposure risks, knowledge required
for performing a pre-check of equipment, and knowledge of
correct and proper blasting techniques is required.

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Abrasive Blasting SOP- 905

Training and c. For Mechanical Supervisors and ExxonMobil Contractor


Communication, Representatives, knowledge in selection and proper disposal of
cont. abrasive agents; selection, maintenance, and storage of
respiratory and personal protective equipment; minimizing dust
exposure to other affected personnel for jobs outside of
designated areas.

Additional The following section applies to all abrasive blasting jobs on storage
Requirements For tanks (for additional reference, see API 2027: Ignition Hazards
Abrasive Blasting Involved in Abrasive Blasting of Atmospheric Storage Tanks in
For Storage Tanks Hydrocarbon Service). This information will aid in the preparation of
storage tanks for the issuance of a Hot Work Permit.

1. The Hot Work Permit may include additional preparation steps or


restrictions, dependent upon the hazards presented by the stored
material, beyond those listed below.

a. Abrasive blasting will not be conducted during periods of


product movement either into or out of the tank. Ensure that
the suction and fill lines have been blocked, chained and
locked, in accordance with SOP 701 Equipment Isolation.
b. All leaking or weeping seams are to be properly caulked to
prevent escaping vapors or liquid. After caulking, the seams
are to be tested for combustible vapors.
c. A 30-pound Ansul and/or fire hose is mandatory.
d. All vents are to be covered with wet sacks to help prevent
vapors escaping or air entering through the vents.
e. Abrasive blasting hose must be of the wire-wrapped, conductive
type and bonded to the tank being abrasive blasted.
2. All open sewers in the immediate area must be covered, vents or
drains must be closed and gas checked.
3. Abrasive blasting is not to be conducted within six (6) feet of
vents, gauge hatches or any other uncovered opening.

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Abrasive Blasting SOP- 905

Primary Users Responsibilities for the following ExxonMobil personnel are detailed in
Responsibilities the following sections.

ExxonMobil 1. Verify the composition of the surface coatings (e.g., lead-base


Mechanical paint, primer) or surface contaminants, prior to beginning work, with
Supervisor or Industrial Hygiene. Industrial Hygiene may deem it necessary for
Representative additional provisions to be incorporated into the abrasive blasting
job depending upon the surface coating.
2. Designate at least two workers be assigned to an abrasive blasting
job, one of whom will serve as the blaster and the other as a kinker.
(The only exception to this would be work conducted at a
designated area, in which case the blaster would be provided with
radio communication, see Definitions Section - Designated Area)
Notify Industrial Hygiene of removal projects.
3. Ensure that all personnel have received the appropriate training to
do assigned duties. Blasters should be trained in the safe and
correct blasting techniques of the equipment. Kinkers should be
properly trained to monitor the blaster, air compressor, warning
alarm systems, and perform any other duties as necessitated by
the job.
4. Ensure that all personnel to work within the identified area have
been fit tested, medically evaluated and have received required
respirator training; that these personnel understand that they are
required to wear the necessary respirators while in this area.
5. Visually conduct a pre-check before abrasive blasting work is
begun that includes the following:
Job Equipment (physical integrity)
Personal Protective Equipment (physical integrity, proper
selection)
Illumination (adequate lighting)
Compressor located such that exhaust air or other
contaminants cannot enter air intake
6. If blasting is required outside of a designated area, then access
barriers such as warning signs and/or traffic cones (and road
blocks if needed) will be placed within a 50-foot radius of the
blasting area. It may be necessary to utilize shielding (see
Definitions Section-Shielding) to minimize the exposure of auxiliary
personnel to dust. While blasting is in progress, other work should
be avoided in this area.
7. Ensure that the abrasive cleaning agent to be used is approved,
containing 1% or less free silica or no free silica (see Definitions
Section - Low-Silica or Non-Silica). No others may be substituted
without the written approval of Industrial Hygiene.

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Abrasive Blasting SOP- 905

Mechanical 8. Safety is contacted for the issuance of a Hot Work Permit, (see
Supervisor or SOP 902, Hot Work in the SOP manual).
Representative,
9. Ensure proper disposal of abrasive waste and removed coatings,
cont.
coordinating this effort with the Waste Coordinator.

Blaster 1. Before blasting begins, the blaster should check all equipment to
ensure it is in proper working order, with no visible damage. If at
any time blasting equipment is found to be in need of repair, the
equipment shall be taken out of service until it is properly repaired
or replaced.
2. Check hood for sanitation. Check the windows on the hood to see
that they are clear and that the rubber seals around the windows
are in good condition. Verify that the interior sock fits closely
around the neck, and that the exterior cape seals with the hood. All
parts of the hood assembly should be in good condition.
3. Verify that the breathing air hoses have the correct fittings and that
they are in proper working order. Also check the condition of the
hose to see that there is no excessive wear or abuse.
4. Check breathing air source. If using a breathing air compressor,
check the first filter for color change. Color change takes place as
a part of the normal process of filtering. The filter should be
changed according to the filter manufacturer's recommendations. If
using breathing air cylinders, check cylinder pressure. Breathing
air should be regulated for the correct pressure, according to hood
manufacturer's recommendations.
5. Check blasting equipment hopper and compressed air source for
proper working order. Also, check hoses to see they are in good
condition, and if the operating trigger on the nozzle shuts off flow
when released.
6. Don appropriate protective equipment to include heavy gloves,
hearing, eye, and head protection, and if needed, fall protection.
7. After the operation is completed, there will be dust particles in the
atmosphere around the blasting area. It is recommended that the
blaster wait a few minutes until the dust has settled before
removing the hood. Depending on hose length, the blaster should
try to walk out of the area before removing respiratory protective
equipment.

Kinker 1. Select, check, and don appropriate respiratory protective


equipment, half face piece air-purifying respirator with HEPA
cartridge.
2. Don appropriate protective equipment to include hearing, eye, head
protection, and Nomex, and if needed, fall protection.
3. Monitor the condition of the breathing air filters and actuation of the
carbon monoxide (CO) filtration/monitoring system throughout the
Refinery.

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Abrasive Blasting SOP- 905

Kinker, cont. 4. Monitor the air intake of the compressor (to ensure that vehicle
exhaust and other similar sources of contamination are maintained
a safe distance away, approximately 15 feet).
5. Monitor the general physical appearance of the blaster throughout
the abrasive blasting job.
6. Ensure that the Blaster's hose remains free of entanglement.
7. Perform any other duties as deemed necessary by the ExxonMobil
Mechanical Supervisor or Representative.

Auxiliary Personnel 1. Select, check, and don appropriate respiratory equipment, half face
piece air-purifying respirator with HEPA cartridge.
2. Don appropriate protective equipment to include hearing, eye, head
protection, and Nomex, and if needed, fall protection.
3. Perform any other duties as deemed necessary by the ExxonMobil
Mechancial Supervisor/ Representative.

Field Safety Conduct random spot-check audits of daily permitted jobs to ensure
Advisors that procedural and other requirements are being followed.

Attachments
N/A

***End of Procedure***

Rev 0, 6/02 UNCONTROLLED DOCUMENT WHEN PRINTED Page 10 of 10

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