Safety Procedures for GRP Pipeline Installation and Lamination

Below are detailed health and safety procedures for GRP pipeline installation and lamination works. The chemical components required for the butt-strap joints of GRP pipes present certain safety and health hazards if not handled well.

Following are the recommendations:

Common Hazards:

Resin: Liquid resin contains styrene which is flammable. Its vapors may cause irritation of eyes, nose and throat. Excessive inhalation may cause dizziness, drowsiness or loss of consciousness.

Catalyst: Methyl ethyl ketone per oxide is a strong oxidizing agent and is a fire and explosion hazard. It is irritant to eyes, skin and mucous membranes, and is known as sensitizer. It shall always be stored in original containers & only small quantity shall be taken to the work place as per site activities/ requirement.

Styrene: ( For tools cleaning) The principal hazard is loss of consciousness in case of excessive inhalation of vapors. Exposure to high vapor concentration may cause cardiac irregularities.

Control Measures:

Work in adequate ventilation. Wear dust / vapor mask while mainly working inside the pipes. All crew members shall use protective / safety glasses and rubber gloves. Long sleeved shirts, long pants and hats of some kinds (depend on client safety requirement) are recommended.

“NO SMOKING “sign in all lamination material storage and working area shall be displayed. All materials and chemicals shall be away from heat source, sparks and open flames.

First Aid Procedure:

Inhalation: Remove the victim to fresh air.

Eyes: Flush exposed eye large amount of flowing water. In case of severity, immediately obtain medical aid from nearest hospital.

Skin: Wash skin with soap using enough volume of water.

Risk Assessments

The Sub-contractor safety officer and site management will meet the terms of Health and Safety regulations equally across all installation work activities. All subcontractors employees to carry out a suitable and sufficient risk assessment of all risks to workers and any others who might be affected by their work activities.

This is for the purpose of identifying the measures he needs to take to comply with the requirements and prohibitions imposed upon him by or under relevant statutory provisions.

In essence this is a requirement to wherever possible remove the risk entirely, or where this is not practicable reduce and control the risk to the lowest level that is reasonably practicable.

Listed below the hazardous materials used for jointing works notifying that the MSDS will be submitted for approval:

1) Fiberglass woven roving in strips of the width required.

2) Resin (promoted but not catalyzed) of the same type as the tank wall materials.

3) Styrene

4) Catalyst

The Resin, Styrene and Catalyst used in making the lamination joints are flammable and may be harmful.

Styrene monomer vapor may cause irritation of the eyes, skin and mucous membranes of the upper respiratory tract. Excessive inhalation may cause loss of consciousness.

Repeated skin contact with polyester resin may cause dermatitis.

Precautionary Measures:

Use with adequate ventilation. Avoid inhalation of vapors and preferably use respirators with filters (chemical usage).

Spilled resin should be absorbed with inert materials such as sand; Resin that may have been mixed with peroxide initiators prior to spillage should be mixed with inert filler and removed to an open area. And allow time to gel and cure.

Fire Hazards:

Liquid polyester resin systems contain styrene which is flammable.

“NO SMOKING” in storage or work areas, store in cool place away from flames, sparks, direct sun light steam pipes or other sources of heat.

Fight fire with foam, carbon dioxide, or dry chemical type extinguishers.

Common Name: Styrene
Hazard: Exposure to excessive styrene vapor concentrations may cause irritation of the eyes, skin and mucous membranes. Direct contact with the liquid may cause blistering of the skin.

Precautionary Measures: Use with adequate ventilation. NO SMOKING in area where materials is stored or used. Avoid contact with skin and excessive inhalation of vapors. To prevent eye and skin
contact use Rubber gloves and safety glass for the technicians at work.

Fire Hazards: Styrene is a flammable liquid.

“NO SMOKING” in storage or work areas, store in cool place away from flames, sparks, direct sun light steam pipes or other sources of heat.

Fight fire with foam, carbon dioxide, or dry chemical type extinguishers.

Common Name: Catalyst
The catalyst is an oxidizing agent and is a fire hazard. It is an irritant to eyes, skin and mucous membranes and is known sensitizer.

Precautionary Measures: Wear protective clothing, rubber gloves and safety glass to prevent eye and skin contact. Use with adequate ventilation. Avoid breathing vapor.

Store in the original containers, in the smallest quantity, isolated from other chemicals and away from heat and open flames.

NO SMOKING” in storage or work areas.

General Safety Rules to follows during site lamination & materials handling:

Sub- Contractor Safety Officer will make sure for all Technicians to fulfill the following safety rules as detailed.

Safety glasses should be worn at all time and by all personal in the vicinity of the lamination operation.

The skin of all technicians handling the materials should be protected with rubber gloves, long sleeve shirts, long pants, paper mask and respirator with cartridge (RC202) filter for the internal lamination works.

The chemicals are flammable and shock sensitive. Care should be taken that they are kept away from open flames or sparks and that are stored separately away from work areas and other flammable materials. They should also protect from heat and direct sun light.

A “NO SMOKING RULE” should vigorously be enforced in all areas where lamination is being made.

All sub-contractor technicians will wear a respirator with filter during the lamination works.

Safe Working in Confined Space

Only authorized to suitable trained personnel shall be allowed to enter into confined spaces (such as pipe line).

No work whatsoever shall be undertaken without first referring to the current Risk Assessment for the work to be undertaken.

A ‘Permit to Enter a Confined Space’ is to be issued by the relevant trained personal or Supervisor or his authorized assistant prior to each and every entry.

Personal Protective Equipment – Gloves, overalls, safety boots, safety helmets, eye protection etc, and is to be worn as appropriate to the task.

Sub-contractor will provide exhaust fan with a size enough to have good air circular ventilation inside the pipe line.

Contractor will provide the gas tester equipment and trained personal to use and monitor the oxygen percentage in the atmosphere. Records and such training shall be maintained by sub-contractor safety officer in cooperation with HSE Managers and will be entered to the permit to work.

Sub-contractor will identify qualified personal for confined space stand by men and to be trained from HSE Managers. His responsibilities to monitor authorized entry to confined space in accordance with the permit to work conditions, to maintain contact with those inside the confined space ant raise the alarm and provide initial controlling the event of any emergency.

Records of any such training shall be mentioned by sub-contractor HSE office.

Each Lamination group of technicians (4 Techs.) should have separate suitable fire extinguisher to use at the time required and be trained to use them.

First aider and paramedic’s response.

Ambulance response and treatment by doctor and or hospital

Proper communication equipments and contact numbers (Emergency contact numbers attached)

Ensure PTW is processed by authorized and Competent persons.

Ensure effective supervision and conduct inspection.

Conduct tool box talk prior to starting work to the force by using the TBT (Tool Box Talks) prompt card. Confirm they all understood the task, hazards and safety precautions and actions to be taken in case of emergency.

Safe Working at Night

All activities shall be followed as bellow:

Equipment shall be checked in good working condition before using.

Trained workers only shall be allowed to perform each task. Adequate supervision shall be provided o enforce procedure and to guard against untrained authorized worker.

Visible access for personnel shall be prepared on the slope surface. All equipment and material shall be located at least 2 meter away from the excavation.

Watchman shall be used and control all equipment to warn personnel or other equipments, motor vehicles to keep safe distance from working equipments.

All vehicles shall have safe distance during excavation works to avoid accident. Watchman shall also used to warn and prevent colliding with each other.

Back alarm is installed on all equipments to serve as warning signal prior to backing out the equipments.

All personnel working in night must wear reflective vests.

Flash light shall be provided to the foreman and supervisor/ watchman.

Safe Loading & Unloading

Provide warning tape or wood cap in all extruding sharp edges.

Unwanted materials should not be pile at the work area.

The workers who perform the job must be trained.

Barricade and signage should be provided in working area.

Always avoid blocking the access with materials.

Perform good house-keeping in the work area

Don’t lift the load beyond the capacity of the equipment.

All material must be arranged in proper place after finishing your job.

Access must be clear.

Transport materials / loading / unloading movements of vehicle

The vehicle should be inspected prior to using.

Ensure periodic maintenance of vehicle.

Do not over speed and avoid sudden breaking.

Ensure proper plan to transport and loaded material.

Plant and vehicle to be operated by experienced and licensed operators / drivers.

Transport to agreed location.

All workers will be ensured to use PPE.

Proper assistance given by the supervisor.

Adherence to lifting and rigging plan.

Licensed driver will be ensured to drive.

Passage of movement will be confirmed to driver.

Crane operator to inspect the area for suitability for staging the crane and space for extending out rigger.

All the lifting equipment and tackles shall be inspected prior to use. All lifts to be carried out by competent rigging crew approved by third party and crane operator, using proper lifting tackles.

Unloading of the materials should be conducted without standing on the material.

The entire job should be properly planned and scheduled in advance to minimize confusion and shortcuts.

Equipment to be in good order and inspected before use by contractor.

Ensure experienced and licensed operators by contractor.

Ensure experienced, competent rigger to control the lifting equipment.

Competent rigger / banks man to attach lifting equipment.

Establish exclusive zone and ensure use of PPE.

Locating of lifting points will be ensured to operator.

Passage of travel will be ensured to operator.

The area under shifting will be cleared without workers and crane to be relocated at a safe area.

Competent rigger will inspect lifting equipments.

Timber, soft or suitable material shall be used between sling belt and steel members.

Safe Scaffolding Requirements

Engage skilled workers for the work.

Inspect all the tools and discard the damaged ones.

Ensure that all workers know use of tool.

Ensure effective supervision and conduct inspection.

Conduct tool box talk prior to starting work to the force by using the TBT (Tool Box Talks) prompt card. Confirm they all understood the task, hazards and safety precautions and actions to be taken in case of emergency.

Ensure PTW is processed by authorized and competent persons.

Anchor always to a lanyard.

Provided proper guard rails.

Never ride of scaffold being removed. Make sure that toe boards and handrails are secure.

Barricade the areas to which objects can fall.

Don’t permit the workers to enter the barricade area.

All Persons should wear the hard hat and adequate PPE

Provide ladder extension of one meter above landing platform.

Use another person to hold the ladder.

Do not use last 2 top rungs.

Materials should not be pile stocked over the platform.

Good housekeeping should be maintained.

Keep Electrical Cord Wire out of the walk away.

Working platform shall be fully planked and tied properly with to board and guard rails.

Provide proper size of platform to suit the working area. Only trained and authorized persons shall work at height.

Follow scaff-tag system to identify the status of scaffolding by the trained and competent person.

Safe Excavation Procedure

Safe Work Permits and other pertinent documents shall be secured before any works commence.

Sequence of work shall be discussed during daily toolbox meeting before work commence.

Equipment and tool inspection must be carried out.

Safety Officer assigned in the area to check safe work plan/excavation permit prior to actual excavation.

Permit should be placed at the work site.

Excavate in accordance with the approved Work procedure.

Observe proper sloping/benching

Competent Supervisor to oversee actual excavation.

Back-up/reversing alarm of loader, truck, crane, excavation etc. must always in good condition/operational.

Soft ground / newly back filled areas must be marked / identified.

Provide adequate and appropriate access for personnel.

Use of full body harness and life line / anchorage point.

Providing physical barricade (scaffold tubes or equivalent).

Install safety warning signs – “Danger Deep Excavation”.