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INTRODUCTION
Paints have been manufactured since prehistoric times, but until
recently they were highly expensive and thus were mainly used for artwork.
It is only since the nineteenth century that houses have commonly been
painted. Today paints are used for colorings and protecting many surfaces,
including houses, cars, road markings and underground storage vessels.
Each of these different applications requires a different sort of paint, and it is
these differences in composition that are the focus of this article. Paint is
essentially composed of a binder, pigment and solvent.
Binder
s
The binder exists to hold the pigment to the surface. The binder is a
polymeric substance, and is either dissolved in the paint or suspended in it
by emulsifiers.
Drying oils
These were used until the 1960's, and are natural oils that polymerize as
they dry. They take a long time to dry and have variable properties as the
balance of oils varies from crop to crop.
Alkyd resins
Alkyd resins are the most common resins to be used in solvent-based paints.
They are basically polyesters and are used for both air-drying and heat-cured
paints.
These are emulsions in water and are the most common water-based binders
for use in household paint.
Epoxy resins
These resins are based on polymers containing the simple organic compound
'oxirane' (ethylene oxide). A variety of other components are added to give a
wide range of properties.
Polyurethanes
2. CONTROLS
Manuals
For each stage of the operation, from the receipt of the order to
the delivery of the products, the detailed procedures are set out
in manuals. These are followed and the requisite actions
recorded as being completed, so there is no doubt about what is
required and what h a s been done.
Production Instruction Document
An instruction document is issued for each batch of coating
manufactured. This details the actions required by the
production staff for manufacture. Any critical feature of the
process is highlighted by requiring a specific action by the
operator, which is recorded as being completed. Examples of
such documents appear as appendices to 6.2.1.
Product Test Specification
Product
Test
Specifications
exist
for
every
coating
manufactured.
They list the tests, which are required during
manufacture and on completion to ensure the batch meets the
coating specification, and is fit for use.
The specifications contain, where appropriate, the permissible
tolerances for each test.
The relevant test must include a reference to a specific method
contained in a manual of test methods detailing the procedure
to be used.
3. QUALITY OF PROCEDURAL PROBLEMS
In the event of a failure at any stage of the process or a complaint, a
procedure exists to find the cause, rectify the problem, and if
necessary make the appropriate improvement(s) to the manuals or
other controls to prevent a repetition. A person is appointed who is
independent of the production and quality control functions to accept
responsibility for the rectifi cation processes. He is referred to as the
Quality Manager.
Delivery Point
Price
6. PRODUCTION
Objectives
To convert raw materials safely and efficiently into the finished
product(s) which meet the declared specification(s) and ensure
that the labeling and packaging meets the requirements of the
customer.
The Formula and the Process
This will be designed so that the product meets the required quality
standards without any undue adjustments.
Manufacturing Instruction Document
A manufacturing instruction document is issued with each
batch giving precise details of the raw materials with the
quantities to be used. It highlights the critical parts of the
process and provides the facility for the requisite actions to
be recorded and certified by the operator. It is
acknowledged
that the variety of coatings manufactured
coupled with the many different processes used, prohibits
the production of manufacturing guidelines. A coating can
be manufactured successfully in a number of ways using
different equipment.
Prevailing conditions and batch size
will require significant modifications to the process.
The Formula
This only allows the use of approved raw materials in the
quantities and proportions necessary to obtain the quality
of product required.
Equipment
The equipment used is known to be appropriate to perform the
task required of it.
Maintenance
It is kept in good repair with a documented inspection and
maintenance schedule appropriate to the particular piece
of equipment.
Cleanliness
The u s e o f plant dedicated to the manufacture of food contact
coatings is most desirable but not essential. Where p o s s i b l e
plant should be used for the production of a single product or family
of products only.
Written plant cleaning and inspection procedures exist to ensure
removal of any undesired material from all equipment prior to
the manufacture of the coating. Filtration is an integral part of the
process to remove unwanted solid particles at the end o f t h e
process.
Health, Safety, and the Environment
The working conditions and manufacturing equipment are
designed
and operated to c o n f o rm to t h e relevant
requirements
of
the
National
government
and
agency.
7. PACKAGING
Specification
The packaging is selected, where possible, in agreement with
the customer, to meet the customers use requirements. It
conforms to appropriate National and UN requirements for the
nature of the product packed and the means of transport.
Cleanliness
New containers should be inspected for cleanliness.
Returned containers should be cleaned to avoid
contamination with another product or foreign bodies.
Accurate Filling
any
When necessary, s u i t a b l e
ensure accurate filling.
Labeling
Each container for dispatch should carry labels showing:
8. WAREHOUSING
Conditions
Raw materials and finished coatings should be stored in
conditions to prevent, as far as possible, any deterioration of the
material.
Raw Materials
Raw materials should be stored in appropriate containers in a
manner to prevent contamination and spillage. They should be
clearly marked with the agreed product description and or code,
which include a reference to the delivery date.
Areas should be a ll oc a t e d to approved materials and when
tested in- house they should be marked as such.
Untested materials should be quarantined until approved or
rejected.
Rejected
materials
should
be
marked
and
segregated. A procedure must exist to prevent their use in
production. Preferably they should be kept in a designated
area.
Materials should be used on a first in first out basis.
Finished Coatings
LOCAL COMPANY:
Manufacturing Process:
A. Raw Material
B. Process
Let Down In a separate, larger, vat the rest of the paint (resin,
solvent and additives) is combined and mixed. At this stage, final
additions are made and added in.
minimize dust generation in the plant. They also implement a Basura mo,
Sagot ko program in the vicinity which helps the neighborhood to manage
their waste.
SAFETY MANAGEMENT
Atlantic Coatings, Inc. is a safety first community. They have an in house
firetruck and trained firefighting crew which consists of the employees
themselves. Since cameras may be a source of ignition, it is not allowed
inside the production facility. Personal Protective Equipment (PPE) must be
worn at all times inside the premises. PPE includes safety glasses, long
sleeves buttoned, maong pants, safety shoes, masks since the materials
they are working on have strong odor, and earplugs to counter the noise
produced by the equipment. The plant is a strict smoke-free facility and a
smoking area for smoking employees is provided outside the plant.
Green lanes are painted on the floor which serves as the pedestrian area
inside the whole plant. Since there are many mobile equipment in the plant,
the green lane serves as a safe area for employees and visitors.
WARE HOUSING
Raw materials and finished coatings should be stored in conditions to
prevent, as far as possible, any deterioration of the material manner to
prevent contamination and spillage. They should be clearly marked with the
agreed product description and or code, which include a reference to the
delivery date.
Areas should be allocated to approve materials and when tested in house
they should be marked as such. Untested materials should be quarantined
until approved or rejected. Rejected materials should be marked and
segregated.
INTRODUCTION
Chemicals are used in virtually all work activities, thus presenting
certain chemical risks in a large number of workplaces all over the world.
Many thousands of chemicals are used in substantial quantities, and many
new chemicals are also introduced into the market each year. It is therefore
an urgent task to establish a systematic approach to safety in the use of
chemicals at work.
Hand Protection
Skin contact is a potential source of
exposure to toxic materials; it is
important that the proper steps be taken
to prevent such contact. Most accidents
involving hands and arms can be
classified under four main hazard
categories: chemicals, abrasions, cutting,
and heat. There are gloves available that
can protect workers from any of these
individual hazards or any combination
thereof.
Advantages
Disadvantages
Use Against
Natural Rubber
Bases, alcohols,
dilute water
solutions; fair vs.
aldehydes,
ketones.
Physical
properties
frequently
inferior to natural
rubber
Same as natural
rubber
Plasticizers can
be stripped;
frequently
imported may be
poor quality
Natural Rubber
Blends
Poly Vinyl
Chloride
Neoprene
Low cost,
dexterity, better
chemical
resistance than
natural rubber
vs. some
chemicals.
Low cost, very
good physical
properties,
medium cost,
medium chemical
resistance
Medium cost,
Oxidizing acids,
Nitrile
medium chemical
resistance,
medium physical
properties
N/A
anilines, phenol,
glycol ethers
Low cost,
excellent
physical
properties,
dexterity
Oils, greases,
aliphatic
chemicals,
xylene,
perchloroethylene
, trichloroethane;
fair vs. toluene
Butyl
Poly Vinyl
Alcohol
Specialty glove,
polar organics
Expensive, poor
vs.
hydrocarbons,
chlorinated
solvents
Glycol ethers,
ketones, esters
Specialty glove,
resists a very
broad range of
organics, good
physical
properties
Very expensive,
water sensitive,
poor vs. light
alcohols
Aliphatics,
aromatics,
chlorinated
solvents, ketones
(except
acetone), esters,
ethers
Extremely
expensive, poor
physical
Aromatics,
chlorinated
solvents, also
Fluoro elastomer
Specialty glove,
organic solvents
properties, poor
vs. some
ketones, esters,
amines
aliphatic and
alcohols
Excellent
chemical
resistance
Norfoil (Silver
Shield)
Goggles
These
are
tight-fitting
eye
protection that completely cover the
eyes, eye sockets and the facial area
immediately surrounding the eyes and
provide protection from impact, dust and
splashes. Some goggles will fit over
corrective lenses.
Face Shield
These transparent sheets of plastic
extend from the eyebrows to below the
chin and across the entire width of the
employee's head. Some are polarized for
glare protection. Face shields protect
against nuisance dusts and potential
splashes or sprays of hazardous liquids.
Foot Protection
Calf-length rubber boots give protection against a wide range of
dilute pesticide products. Leather footwear is unsuitable because it
absorbs some pesticide products and cannot be decontaminated.
Trousers should be worn outside the boots so that spills and splashes
do not fall into them.
Review
The extent of the training and instruction received and required should
be reviewed and updated simultaneously with the review of the
working systems and practices.
The review should include the examination of:
in the case of a hazardous chemical, is identical to that used on the label and
the chemical safety data sheet. Inclusion of the name of the supplier on the
shipped container or packaging is recommended.
The purpose of the label is to give essential information on:
its hazards;
Trade Names;
Hazard symbols;
Nature of the special risks associated with the use of the chemical;
Safety Precautions
Class of
Chemicals
Compressed
GasesFlammable
(Includes
Combustible)
Compressed
GasesReactive
(Includes
Oxidizing)
Corrosive Acids
Corrosive Bases
Explosives
Recommended
Storage
Method
Chemical
Example
Incompatibles
See Safety
Data Sheets in
all cases
Methane,
Acetylene,
Hydrogen
Oxidizing and
toxic compressed
gases, oxidizing
solids.
Store in a cool,
dry area at least
20 feet away
from flammable
gases and
liquids. Securely
strap or chain
cylinders to a
wall or bench top
Oxygen, Chlorine,
Bromine
Flammable
Gasses
Store in a
separate,
lined/protected
acid storage
cabinet or plastic
secondary
container.
Hydrochloric acid,
Sulfuric acid,
Chromic acid, Nitric
acid, Acetic acid,
trichloroacetic acid,
lactic acid
Flammable
liquids,
flammable solids,
bases and
oxidizers.
Store in a
separate storage
cabinet.
Ammonium
hydroxide,
potassium
hydroxide, sodium
Store in a secure
location away
from all other
chemicals. Do
not store in an
area where they
can fall.
Ammonium
nitrate, nitro urea,
sodium azide,
trinitroaniline,
trinitroanisole,
trinitrobenzene,
trinitrophenol/picri
c acid,
trinitrotoluene
(TNT)
Oxidizers and
Acids
All other
chemicals
Flammable
Liquids
Store in a
flammable
storage cabinet
Acetone, Benzene,
Diethyl
ether, Methanol,
Ethanol, Hexanes,
Toluene
Oxidizers and
Acids
Flammable Solids
Store in a
separate dry cool
area away from
oxidizers,
corrosives
Phosphorus,
carbon, charcoal
Oxidizers and
Acids
Water Reactive
Chemicals
Store in a cool
dry location.
Protect from
water and the
fire sprinkler
system. If
applicable
Store in a spill
tray inside a non
combustible
cabinet, separate
from flammable
and combustible
materials
Sodium metal,
potassium metal,
lithium metal,
lithium aluminum
hydride
Sodium
hypochlorite,
benzoyl peroxide,
potassium
permanganate,
potassium
chlorate,
potassium
dichromate
Separate from
reducing agents,
flammables,
combustibles and
organic
materials.
Oxidizers
Env
ironmental, Health, and Safety Guidelines for
Petroleum Refining
INTRODUCTION
The Environmental, Health, and Safety (EHS) Guidelines are technical
reference documents with general and industry-specific examples of Good
International Industry Practice (GIIP). The applicability of the EHS Guidelines
should be tailored to the hazards and risks established for each project on
the basis of the results of an environmental assessment in which site-specific
variables, such as host country context, assimilative capacity of the
environment, and other project factors, are taken into account. The
applicability of specific technical recommendations should be based on the
professional opinion of qualified and experienced persons.
Applicability
The EHS Guidelines for Petroleum Refining cover processing operations
from raw crude oil to finished products, including refinery fuel gas, liquefied
petroleum gas (LPG), Mo-Gas, kerosene, diesel oil, heating oil, fuel oil,
bitumen, asphalt, waxes, sulfur, pet-coke, and intermediate products.
Occupational Health and Safety
Facility-specific occupational health and safety issues should be
identified based on job safety analysis or comprehensive hazard or risk
assessment, using established methodologies such as a hazard identification
study [HAZID], hazard and operability study [HAZOP], or a quantitative risk
Process Safety
Oxygen-deficient atmosphere
Chemical hazards
Process Safety
Process safety programs should be implemented, due to industryspecific characteristics, including complex chemical reactions, use of
hazardous materials (e.g. toxic, reactive, flammable or explosive
compounds), and multi-step reactions.
Process safety management includes the following actions:
Oxygen-Deficient Atmosphere
The potential release and accumulation of nitrogen gas into work
areas may result in the creation of asphyxiating conditions due to the
procedures
with
Chemical Hazards
Releases of hydrofluoric acid, carbon monoxide, methanol and
hydrogen sulfide may present occupational exposure hazards.
Hydrogen sulfide leakage may occur from amine regeneration in amine
treatment units and sulfur recovery units. Carbon monoxide leakage
may occur from Fluid and Residue Catalytic Cracking Units and from
the syngas production section of the Hydrogen Plant. Carbon monoxide
/ air mixtures are explosive and spontaneous / explosive re-ignition
may occur. Hydrogen sulfide poses an immediate fire hazard when
mixed with air.
Workers may be exposed to potential inhalation hazards (e.g.
hydrogen sulfide, carbon monoxide, VOCs, polycyclic aromatic
hydrocarbons (PAHs) during routine plant operations. Dermal hazards
may include contact with acids, steam, and hot surfaces. Chemical
hazards should be managed based on the results of a job safety
analysis and industrial hygiene survey and according to the
occupational health and safety guidance provided in the General EHS
Guidelines. Protection measures include worker training, work permit
systems, use of personal protective equipment (PPE), and toxic gas
detection systems with alarms.
Hydrofluoric Acid
Workers may be exposed to hydrofluoric acid (HF) in the HF
alkylation unit. Occupational safety measures include the
following:
Minimizing HF hold-up;
sewage
system
to
avoid
The standards prescribed for the petroleum industry was made under
Occupational Safety and Health Standard under AAC 61.1180 named
Petroleum Drilling and Production Standards convened on 1999.
A. Good Manufacturing Process for Personnel
1. Work Clothing
Production facility
equipment.
2. Head Protection
with
hydrocarbon
containing
process
Wellhead platforms.
must have ultraviolet protective coated lenses. Tinted lenses shall not
be used indoors or other areas of reduced ambient light.
4. Hearing Protection
Hearing protection must be utilized when working in areas where noise
levels exceed time weighted average (TWA) of 85 decibels. A scale for
an 8 hours exposure.
Ear Muffs are devices that fit against the head
and enclose the entire external ears. The inside
of the muff cup is lined with acoustic foam
which can reduce noise by as much as 15 to 30
decibels. Ear muffs are often used in
conjunction with ear plugs to protect the
employee from extremely load noises, usually
at or above 105 decibels.
5. Foot Protection
Safety footwear shall be part of the basic PPE for all personnel in the
categories listed below and shall be worn at all times when outside
accommodations, offices, and on the following:
Offshore Production,
Drilling
Construction
Shorebases (warehouses, docks, jettys and storage areas)