Industrial Coatings Application: Creating Zone 1 Safe Work Environment
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There are many reasons to apply coatings and paints to surfaces. One of the most common is corrosion protection for any industrial sector. These include oil and gas pipelines, storage tanks, bridges and highways, other infrastructure, and maritime, to name a few.
The components are in a vast number of settings, such as the corrosive atmosphere of an oil and gas wellhead and gasification plant, extreme cold in Arctic Alaska, and the tropical waters of Brazil. In most situations, workers apply industrial coatings to metal components, but they can also use it to reinforce concrete.
Industrial Coatings Application
Manufacturers often apply their paints and coatings in a paint chamber to control temperature, humidity, and other environmental factors, and to contain overspray. While most coatings are inert after they cure, industrial paints and coatings are highly toxic and easily ingested or inhaled if workers get exposed during application. The paint booth is likely to be in a Zone 1 environment. Effective electronic monitoring of the atmosphere outside the paint booth is necessary to create a safe work environment.
Performance Standards
Industry organizations typically establish performance standards.
NORSOK developed performance standards for the oil and gas industry's marine terminals and platforms. Many other industries, including several U.S.-based departments of transportation, cite the standards for bridges and structures in brackish and marine waterways.
NACE and AMPP also provide coating and paint performance standards.
When selecting a coating, the environment drives appropriate standards to protect the facility or equipment from corrosion. The coating is an engineered barrier against corrosion, reducing the risk of unanticipated and early failure.
Application Mode Creates a Zone 1 Hazardous Atmosphere
There are five different methods to apply industrial coatings and paints. The application method depends on a number of factors, including the type of material, the performance standard requirements, and the availability of a facility to apply coatings. Regardless of the application method, the thickness of the coating and the appropriate drying temperature are critical for meeting performance standards. The temperature and length of time of heat exposure will vary.
- Spray coating: This application method uses a spray gun to apply a thin layer of paint to the surface. A worker inside the paint booth often completes this and may include atomizing the paint to create very small and consistently sized droplets.
- Powder coating: Powder coating provides a very durable surface resistant to abrasion and corrosion. Workers apply the dry coating as they would paint, but the specialized paint gun electrostatically charges the coating to adhere to the metal part. A moderately high-heat oven completes the curing process.
- Dip coating: This is especially effective at coating the entire surface area by fully immersing the part in the coating.
- Brush coating: The brush coating method is more likely to be used in open-air situations, as it involves using a brush on a surface. The coating can create an inhalation issue due to off-gassing.
- Roll-to-Roll coating: This method results in a consistent thin film coating thickness. The curing process may require heat treatment after application.
Monitoring to Protect Worker Safety
Industrial coating applications can create a Zone 1 worker safety issue from the coating or paint itself or during the curing process. Workers apply most coatings, potentially in a Level B SCBA, for protection from inhalation and contact with the coating. Even with efficient air containment systems in the paint booth, the air outside the booth also needs to be monitored for loss of containment that can impact workers.
Continuous electronic monitoring ensures compliance with air quality and discharge regulations, as well as meeting worker safety requirements. This reduces the need for air quality monitoring personnel on the job site and for an immediate work stoppage if there is a loss of containment.
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