OCE13 - Breaking containment – process cleaning operations

Health and Safety Executive

OCE Breaking containment – process cleaning operations Offshore COSHH Control approach R essentials Respiratory protective equipment

This information will help offshore What this sheet covers dutyholders (owners, operators and This sheet describes good practice for internal cleaning of process contractors) to comply with the Control plant and vessels, eg separators, hydrocyclones, pipework etc. It of Substances Hazardous to Health covers the key points you need to follow to help reduce exposure to an Regulations 2002 (COSHH), as amended, to acceptable level, as part of your COSHH assessment. protect workers’ health. Hazards This guidance consolidates good control 3 Process plants and vessels may contain condensate crude oil and gas. practice and reinforces existing knowledge Hydrocarbons can include BTEX (benzene, toluene, ethylbenzene and with additional information. xylenes) mixtures. 3 Health risks include cancer, genetic damage, reproduction effects, and It will help you carry out COSHH sensitisation by inhalation or skin contact. assessments, review existing assessments, 3 The workplace exposure limit (WEL) for benzene is 1 ppm (8-hour deliver training and in supervising activities time-weighted average (TWA)). Keep exposure as far below this as involving substances hazardous to health. reasonably practicable. 3 Hydrogen sulphide (H2S) may also be present in hydrocarbon process It is aimed at staff whose responsibilities plant and vessels, particularly when reservoirs begin to mature and include the management of substances water out (see OCE6). hazardous to health on offshore 3 Mercury may also be present in process plant and vessels (see installations (eg occupational health OCE14). specialists, COSHH assessors, supervisors 3 NORM (naturally occurring radioactive material) may also be present in etc). It is also useful for trade union and process plant and vessels (see ORE1). employee safety representatives. Access Following this guidance is not compulsory 3 Where possible, erect an enclosure or habitat. and you are free to take other action. But 3 Erect barriers and notices. if you do follow this guidance, you will normally be doing enough to comply with Equipment and procedures the law. Health and safety inspectors seek Planning to secure compliance with the law and may refer to this guidance as illustrating good 3 Define the isolation standards and routines for draining, purging and venting. practice. 3 See sheet OCM1 if work is in a confined space. Also see essential information on the back 3 If NORM is present then ensure that your radiation protection supervisor (RPS) has written local rules for the job (see ORE1). of the sheet. 3 See sheet OCE6 if H2S is present. 3 See sheet OCE14 if mercury is present. Control equipment 3 Where possible use alternative cleaning methods without breaking containment, eg sand washing packages.

3 Provide a spillage clean-up kit. 3 Provide for drainage to appropriate drains, eg closed drains. 3 Provide for gas venting to a safe place, eg a flare stack or cold vent. 3 Provide eyewash equipment and an emergency shower close to the work site. 3 Provide enough fresh air to dilute and remove air contaminants. 3 Provide portable hydrocarbon detector in the area. 3 Respiratory protective equipment is normally Control procedures 3 Isolate the line for safe opening. 3 Connect via valves and lock the pipework to the appropriate drain. Purge and drain the fluids. 3 Vent pressurised gases to a safe place. 3 Prove isolation. Carry out pressure build-up (PBU) checks. 3 Drain, purge and flush the system to hazardous open drains. 3 Prove it is free of gas, if necessary have the authorised tester perform the gas test. 3 Workers should break joints gently. In the event of an unexpected release, workers should evacuate the area immediately and raise the alarm. 3 Fit ‘Disturbed joint’ tags on broken joints. 3 Fit and leak-test blind flanges within 12 hours if the work is not finished. 3 Never allow pipe ends to remain open. 3 Test for leakage on remaking the joint. Personal protective equipment (PPE) – see OCM3 3 All PPE must be easy to decontaminate, eg washable. 3 Ensure that all items of PPE are compatible. Respiratory protective equipment (RPE) – see OCM4 3 Provide a filtering respirator or breathing apparatus, CE marked with an assigned protection factor of at least 40.

Other protective equipment 3 Provide a slicker suit worn over boots, nitrile gloves, and a visor if the RPE does not have one.

Maintenance, examination and testing Checking and maintenance 3 Make and follow schedules for preventative maintenance of plant and monitoring equipment. 3 Before each use, check that portable monitors are fully charged and working properly. 3 Check for signs of damage to control equipment before starting work. RPE 3 Examine and test RPE thoroughly at least monthly and infrequently used RPE at least three monthly. Replace worn parts.

3 Check the airflow and air quality to air-fed RPE at least once every Employee checklist three months, or before use. Check in-line filters. Is your radiation 3 Ensure that breathable air compressors take in clean air. passbook up to date? Is the equipment in good Records condition and working 3 Keep records of all examinations and tests for at least five years. properly? Is your portable/personal Exposure monitoring alarm fully charged and 3 Monitor the air for benzene and H2S by meter, after venting. working properly? 3 Use personal monitoring results to decide if you need to carry out Is your respirator working biological monitoring for benzene. properly? Check it every 3 Monitor to show that workers, PPE, equipment and areas are time. decontaminated to background levels of radiation. Look for signs of leaks, 3 Provide radiation workers with personal dosimeters, changed once a wear and damage before month. every job. Do you have a spill clean- Cleaning and housekeeping up kit handy? 3 Place a temporary bund to contain any spillage. If you find any problem, 3 Clear up small spills with inert absorbent pads. Dispose as hazardous get it fixed. Don’t just waste. carry on working. 3 Wash all PPE and test to show that it has been decontaminated. Discard single-use gloves 3 Label bags of dirty clothing to warn the laundry about the hazard. every time you take them off. Discard other gloves Waste at the end of the shift. 3 Seek advice from the radiation protection advisor (RPA) for NORM Wash hands before disposal. eating, drinking or using 3 Any waste discharged to the sea must comply with an environmental the lavatory. licence. 3 Drain liquid residues to appropriate drains through hoses and valve connectors. 3 Residues are ‘hazardous waste’. Label containers clearly – include a UN number where appropriate. Store and dispose of waste safely.

Personal decontamination and skin care 3 Provide warm water, mild skin cleansers, nailbrushes, and soft paper, fabric towels or hot air for drying. Avoid abrasive cleansers. 3 Tell workers to wash hands before every break. 3 Provide pre-work skin creams that will make it easier to wash dirt from the skin, and after-work creams to replace skin oils.

Caution: ‘Barrier creams’ or ‘liquid gloves’ do not provide a full barrier.

Health surveillance 3 Conduct low-level health surveillance for dermatitis involving skin checks by suitably trained responsible person. 3 Ask your RPA for help in deciding the workers’ classification for ionising radiation work. 3 Radiation workers must be certified as fit to work with ionising radiation. 3 Outside workers must have a radiation passbook. Keep this up to date.

Training and supervision Other hazards 3 Provide supervision – ensure that safe work procedures are followed. n Flammability

3 Check that PPE use follows the local rules. n Hydrogen sulphide (H S) 2

3 You need a trained RPA. n Mercury

3 Tell workers, including maintenance workers, what the hazards and n Substances harmful to the

risks are. marine environment 3 Explain the dangers of NORM. Further information 3 Training includes toolbox talks on: Respiratory protective n how to use equipment properly; equipment at work: A practical n how to use the benzene monitor; guide HSG53 (Third edition) n how to react to alarms and evacuate safely; HSE Books 2005 n how to use RPE and check that it is working; ISBN 978 0 7176 2904 6 n how to clean up spills correctly; and www.hse.gov.uk/pubns/books/ n what to do if something goes wrong. hsg53.htm 3 Involve managers and supervisors in health and safety training. Developing process safety Essential information indicators: A step-by-step guide OCE0 Advice for managers for chemical and major hazard OCM1 Confined spaces industries HSG254 HSE Books OCM3 Personal protective equipment (PPE) 2006 ISBN 978 0 7176 6180 0 OCM4 Respiratory protective equipment (RPE) www.hse.gov.uk/pubns/books/ OCE6 if hydrogen sulphide is present hsg254.htm ORE1 if NORM is present Workplace exposure limits EH40 OCE14 if mercury is present www.hse.gov.uk/coshh/table1.pdf

Other legislation You can find the full Offshore Radioactive Substances Act 1993 COSHH essentials series at www.hse.gov.uk/coshh/index.htm

This guidance was developed by representatives from the UK offshore oil and gas industry and trade unions, with HSE.

© Crown copyright 2011 Published by the Health and Safety Executive 03/11