Dipping And Coating Operations: Dipping And Coating Operations 1910.122 - 126, Subpart H James E. Roughton, CSP, CRSP, CHMM www.asse-ga.org


Summary: Summary Rule developed to accomplish Rewrite former standards in plain language Consolidate former requirements Increase compliance options


Coverage and Definitions -1910.123 : Coverage and Definitions -1910.123


Does This Rule Apply to Me?: Does This Rule Apply to Me? When a dip tank contains a liquid other than water When you use a liquid or vapors to: Clean or coat Alter the surface Change the characteristic Draining or drying an object,dipped or coated


What Operations Are Covered? : What Operations Are Covered? Paint dipping Electroplating Pickling Quenching Tanning Degreasing


Operations Covered (Continued): Operations Covered (Continued) Stripping Cleaning Roll coating Flow coating Curtain coating


What Operations Are Not Covered?: What Operations Are Not Covered? An operation that only uses a molten material Alloy Salt


How Are Terms Defined?: How Are Terms Defined? Adjacent area Any area within 20 feet of a vapor area that is not separated by tight partitions Approved Designated equipment - listed/approved by a nationally recognized testing laboratory Autoignition temperature The minimum temperature required to cause self-sustained combustion, independent of any other source of heat


Terms Defined (Continued): Terms Defined (Continued) Combustible liquid A liquid with a flash point of 100 deg.F or > Dip tank A container holding a liquid other than water and used for dipping or coating An object may be immersed (or partially immersed) or it may be suspended in a vapor area Flammable liquid A liquid with a flashpoint < 100 deg.F


Terms Defined (Continued): Terms Defined (Continued) Flashpoint The minimum temperature where a liquid gives off a vapor in sufficient concentration to ignite Lower flammable limit (LFL) The lowest concentration of a material that will propagate a flame Expressed as a % by volume of the material in air (or other oxidant)


Terms Defined (Continued): Terms Defined (Continued) Vapor area Any tank, including drain boards, drying or conveying equipment, and any surrounding area where the vapor concentration > 25% of the LFL You The employer, as defined by the occupational safety and health act of 1970


General Requirements -1910.124 : General Requirements -1910.124


What Construction Requirements Apply to Dip Tanks? : What Construction Requirements Apply to Dip Tanks? Any container that must be strong enough to withstand any expected load


What Ventilation Requirements Apply to Vapor Areas? : What Ventilation Requirements Apply to Vapor Areas? Keep airborne concentration < 25% of its LFL Meet levels specified Subpart Z Use of tank covers or floating materials


When You Use Mechanical Ventilation?: When You Use Mechanical Ventilation? Must conform with standards incorporated by reference: ANSI NFPA ACGIH Draw the flow of air into a hood or exhaust duct


Mechanical Ventilation (Continued): Mechanical Ventilation (Continued) Tanks must have an independent exhaust system unless the combination of substances being removed will not cause a: Fire Explosion Chemical reaction


What Requirements Must I Follow to Recirculate Exhaust Air? : What Requirements Must I Follow to Recirculate Exhaust Air? Can not recirculate exhaust air when substance poses a health hazard to employees > 25% the LFL


Recirculate Exhaust Air (Continued): Recirculate Exhaust Air (Continued) Exhausted air recirculated using flammable or combustible liquids is: Free of any solid particulate Monitored by approved equipment Sounds an alarm, automatically shuts down when the vapor concentration > 25% the LFL


What Must I Do When I Use an Exhaust Hood? : What Must I Do When I Use an Exhaust Hood? Provide area with a volume of outside air that is at least 90 % of the volume of the exhaust air Outside air supply does not damage exhaust hoods


What Requirements Must I Follow When an Employee Enters a Dip Tank? : What Requirements Must I Follow When an Employee Enters a Dip Tank? Meet the entry requirements for permit-required confined spaces


What First-aid Procedures Must My Employees Know? : What First-aid Procedures Must My Employees Know? The first-aid procedures that are appropriate for the operation


What Hygiene Facilities Must I Provide? : What Hygiene Facilities Must I Provide? Lockers or other storage space to prevent contamination of employee's street clothes Emergency shower and eye-wash station close to the operation Can use water hose at least 4’ and at least 3/4” thick, a quick-opening valve, and a pressure of 25 lbs. psi or < At least one basin with a hot-water faucet for every 10 employees


What Treatment and First Aid Must I Provide?: What Treatment and First Aid Must I Provide? A physician's approval before an employee with a sore, burn, or other skin lesion that requires medical treatment works in a vapor area Treatment by a properly designated person of any small skin abrasion, cut, rash, or open sore Appropriate first-aid supplies located near the operation Employees who work with chromic acid, periodic examinations of exposed body parts, especially their nostrils


What Must I Do Before an Employee Cleans a Dip Tank?: What Must I Do Before an Employee Cleans a Dip Tank? Drain the tank, open the cleanout doors Ventilate and clear any pockets where hazardous vapors may have accumulated


What Must I Do to Inspect and Maintain My Dipping or Coating Operation? : What Must I Do to Inspect and Maintain My Dipping or Coating Operation? Inspect hoods and ductwork of ventilation system for corrosion or damage: At least quarterly during operation Prior to operation after a prolonged shutdown Ensure that the airflow is adequate: At least quarterly during operation Prior to operation after a prolonged shutdown


Inspect and Maintain (Continued): Inspect and Maintain (Continued) Periodically inspect all equipment Covers Drains Overflow piping Electrical Fire-extinguishing systems Promptly correct any deficiencies


Inspect and Maintain (Continued): Inspect and Maintain (Continued) Provide mechanical ventilation or respirators to protect employees from exposure to toxic substances during Welding Burning Open-flame work Clean solvents and vapors before permitting welding, burning, or open-flames


Additional Requirements for Flammable or Combustible Liquids - 1910.125 : Additional Requirements for Flammable or Combustible Liquids - 1910.125


Flammable or Combustible Liquids: Flammable or Combustible Liquids Must comply 1910.123, 124, 125, and126 Must comply if: Flashpoint of flammable or combustible liquid is 200 deg. F or > Liquid is heated as part of the operation Heated object is placed in the liquid


What Type of Construction Material Must Be Used in Making My Dip Tank? : What Type of Construction Material Must Be Used in Making My Dip Tank? Noncombustible material


When Must I Provide Overflow Piping? : When Must I Provide Overflow Piping? Properly trapped overflow piping that discharges to a safe location for: A capacity > 150 gallons A liquid surface area > 10 feet


Overflow Piping (Continued): Overflow Piping (Continued) Overflow piping is at least 3” in diameter and has sufficient capacity to prevent the tank from overflowing Piping connections on drains and overflow pipes allow ready access to the interior of the pipe for inspection and cleaning Bottom of the overflow connection is at least 6” below the top of the tank


When Must I Provide a Bottom Drain?: When Must I Provide a Bottom Drain? For tanks that contain > 500 gallons of liquid, unless: The tank is equipped with an automatic closing cover The viscosity of the liquid at normal atmospheric temperature does not allow the liquid to flow or be pumped easily


Bottom Drain (Continued): Bottom Drain (Continued) Must ensure that the bottom drain: Will empty the dip tank during a fire Has pipes that permit the contents to be removed in 5 minutes Is properly trapped Discharges to a safe location


Bottom Drain (Continued: Bottom Drain (Continued Must be capable of manual and automatic operation Manual operations must be from a safe and accessible location Must ensure that automatic pumps are used when gravity flow from the bottom drain is impractical


When Must My Conveyor System Shut Down Automatically?: When Must My Conveyor System Shut Down Automatically? If a conveyor system is used, the system must shut down automatically: If there is a fire If the ventilation rate drops below requirements


What Ignition and Fuel Sources Must Be Controlled?: What Ignition and Fuel Sources Must Be Controlled? In each vapor area and any adjacent area: All electrical wiring and equipment conform requirements of Subpart S Except as permitted in 1910.126 There are no flames, spark-producing devices, or other surfaces that are hot enough to ignite vapors


Ignition and Fuel Sources (Continued): Ignition and Fuel Sources (Continued) Portable container used to add liquid to the tank is electrically bonded and grounded Heating systems used in a drying operation that could cause ignition: Is installed in accordance with NFPA Has adequate mechanical ventilation that operates before and during drying operation


Ignition and Fuel Sources (Continued): Ignition and Fuel Sources (Continued) Shuts down automatically if any ventilating fan fails to maintain adequate ventilation All vapor areas are free of combustible debris Rags and other contaminated material placed in approved waste cans immediately after use Waste can contents are properly disposed of at the end of each shift Post "no smoking" sign near each tank


What Fire Protection Must I Provide? : What Fire Protection Must I Provide? Required for: Any tank with a capacity of at least 150 gallons or a liquid surface area of at least 4’ Any hardening or tempering tank with a capacity of at least 500 gallons or a liquid surface area of at least 25’


Fire Protection (Continued): Fire Protection (Continued) For vapor areas, you must provide: Manual fire extinguishers for flammable and combustible liquid fires Automatic fire-extinguishing system, Subpart L


Fire Protection (Continued): Fire Protection (Continued) May substitute a cover that is closed by an approved automatic device for the automatic fire-extinguishing system if the cover: Can also be activated manually Is noncombustible or tin-clad, with the enclosing metal applied with locked joints Is kept closed when the tank is not in use


To What Temperature May I Heat a Liquid in a Dip Tank? : To What Temperature May I Heat a Liquid in a Dip Tank? Must maintain the temperature of the liquid: Below the liquid's boiling point At least 100 deg. F below the liquid's autoignition temperature


Additional Requirements for Special Dipping and Coating Operations - 1910.126: Additional Requirements for Special Dipping and Coating Operations - 1910.126 In addition to the requirements in 1910.123 -125, must comply with any requirement that applies to your operation


What Additional Requirements Apply to Hardening or Tempering Tanks?: What Additional Requirements Apply to Hardening or Tempering Tanks? Must ensure that hardening or tempering tanks: Are located as far as practicable from furnaces Are on noncombustible flooring Have noncombustible hoods and vents for venting to the outside Vent ducts must be treated as flues and kept away from combustible materials, particularly roofs


Hardening or Tempering (Continued): Hardening or Tempering (Continued) Must equip each tank with an alarm that will sound if the temperature of the liquid comes within 50 deg. F of its flashpoint (the alarm set point) When practicable, provide each tank with a limit switch to shut down the conveyor supplying work to the tank


Hardening or Tempering (Continued): Hardening or Tempering (Continued) If the temperature of the liquid can exceed the alarm set point, equip the tank with a circulating cooling system If the tank has a bottom drain, it may be combined with the oil-circulating system Must not use air under pressure when filling the tank or agitate liquid


What Additional Requirements Apply to Flow Coating?: What Additional Requirements Apply to Flow Coating? Must use a direct low-pressure pumping system or a 10-gallon or < gravity tank to supply the paint for flow coating In case of fire, an approved heat-actuated device must shut down the pumping system Must ensure that the piping is substantial and rigidly supported


What Additional Requirements Apply to Roll Coating, Roll Spreading, or Impregnating?: What Additional Requirements Apply to Roll Coating, Roll Spreading, or Impregnating? When using a flammable or combustible liquid with a flashpoint < 140 deg. F, prevent static electricity by: Bonding and grounding all metallic parts (including rotating parts) Installing static collectors Maintaining a conductive atmosphere (for example, one with a high relative humidity)


What Additional Requirements Apply to Vapor Degreasing Tanks?: What Additional Requirements Apply to Vapor Degreasing Tanks? Must ensure that the condenser or vapor-level thermostat keeps the vapor level at least 36” or 1/2-half the tank width, whichever is less, below the top of the tank


Vapor Degreasing (Continued): Vapor Degreasing (Continued) When gas as fuel is used to heat the tank liquid, prevent solvent vapors from entering the air-fuel mixture Make the combustion chamber airtight (except for the flue opening) Flue must be made of corrosion-resistant material It must extend to the outside Must install a draft diverter if mechanical exhaust is used on the flue


Vapor Degreasing (Continued): Vapor Degreasing (Continued) Must not allow the temperature of the heating element to cause a solvent or mixture to decompose or to generate excessive amount of vapor


What Additional Requirements Apply to Cyanide Tanks? : What Additional Requirements Apply to Cyanide Tanks? Cyanide tanks must have a dike or other safeguard to prevent cyanide from mixing with an acid if a dip tank fails


Additional Requirements For Spray Cleaning And Degreasing Tanks? : Additional Requirements For Spray Cleaning And Degreasing Tanks? If you spray a liquid in the air over an open-surface cleaning or degreasing tank, control the spraying by: Enclosing the spraying operation Using mechanical ventilation to provide enough inward air velocity to prevent the spray from leaving the vapor area


What Additional Requirements Apply to Electrostatic Paint Detearing?: What Additional Requirements Apply to Electrostatic Paint Detearing? Must use only approved electrostatic equipment in paint-detearing operations Electrodes must be substantial, rigidly supported, permanently located, and effectively insulated from ground by nonporous, noncombustible, clean, dry insulators Must use conveyors to support any goods being paint deteared


Electrostatic Paint (Continued): Electrostatic Paint (Continued) Must ensure that material being electrostatically deteared are not manually handled Must maintain a minimum distance of twice the sparking distance between material being electrostatically deteared and the electrodes or conductors of the electrostatic equipment Minimum distance must be displayed near the equipment


Electrostatic Paint (Continued): Electrostatic Paint (Continued) Must ensure that the electrostatic equipment has automatic controls that immediately disconnect the power supply to the high-voltage transformer and signal the operator if: Ventilation or the conveyors fail to operate Material being electrostatically deteared come within twice the sparking distance of the electrodes or conductors of the equipment A ground occurs anywhere in the high-voltage system


Electrostatic Paint (Continued): Electrostatic Paint (Continued) Must use fences, rails, or guards, made of conducting material and adequately grounded, to separate paint-detearing operations from storage areas and from personnel


Electrostatic Paint (Continued): Electrostatic Paint (Continued) To protect paint-detearing operations from fire, must have: Automatic sprinklers An automatic fire-extinguishing system conforming to the requirements of Subpart L To collect paint deposits: Provide drip plates and screens Clean these plates and screens in a safe location