OPITO APPROVED STANDARD Blaster-Sprayer Competence Standard · OPITO Approved Standard Blaster-Sprayer ... workplace experience in industrial blasting and painting ... Approved Standard

OPITO APPROVED STANDARD

Blaster-Sprayer

Competence Standard

OPITO Standard Codes:

Initial Assessment: 9125 Re-assessment: 9126

OPITO Approved Standard Blaster-Sprayer Competence

© OPITO

Blaster-Sprayer Rev.1 (Dec 2011) Amendment 1 (Jan 2013) Page 2 of 49

OPITO STANDARDS OPITO is an Industry-owned not-for-profit organisation that exists solely to service the needs of the Oil and Gas Industry. OPITO is employer led in all aspects of what it does, therefore all standards development activities are at the behest of industry employers. The standards are driven by the needs of employers to help create a safe and competent workforce. This standard is owned by the Oil and Gas Industry and maintained by OPITO who are the nominated custodians of all Industry standards within the OPITO portfolio which carry the OPITO logo. The contents of this document were developed by an industry workgroup facilitated and supported by OPITO. The workgroup consisted of representation from a cross section of oil and gas Industry employers, discipline experts working within the industry and members of the OPITO Approved Training network. This standard has been verified and accepted through the governance and integrity management model for OPITO standards. Guidance on this standard is available by contacting OPITO at: Standards Enquiries

This standard has been designed to accommodate global variations in national legislation and regulations. In the absence of relevant national legislation and regulations, OPITO approved centres should use legislative and regulatory Criteria specified within this Standard

© OPITO All rights reserved. No part of this publication may be reproduced, stored in a retrieval or information storage system, or transmitted in any form or my any means, mechanical, photocopying, recording or otherwise, without prior permission in writing of the publishers.

http://www.opito.com/contact/


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AMENDMENTS

Amendments and Date Section /pages

Changes made by

Checked by Approved by

Revision 0 (March 2008) 1 Updated text to reflect revised

content after Trainee Blaster-Sprayer Training Pilot Course 18-04-08

All T. Wilson P. Crowther P. Crowther

2 Changed footer to reflect amendment numbering scheme 15-Dec 2008

All except title page

T. Wilson J. Cameron M. Duncan

3 Simplified assessor qualifications 19-Dec 2008

7 T. Wilson J. Cameron

J. Cameron

Rev.1 Converted from an OPITO non-certified standard to an OPITO-certified standard at Industry’s request and full review completed. Revision 1

(Dec 2011)

All M. Carr Industry Work

Group P. Lammiman

1 Replaced Course Code with Standard Code in Title Page and amended reference to ‘course identification code’ with ‘OPITO registration code’ under section D.3 Certification - to align with other OPITO standards Revision 1 Amendment 1 10-January 2013

Title Page, page 26

M. Foo M. Carr P. Lammiman

Any amendments made to this standard by OPITO will be recorded above.


© OPITO


Contents

Introduction .............................................................................................................................. 5

SECTION A The Blaster-Sprayer Competence Assessment ............................................ 7

A.1 Target Group for the Blaster-Sprayer Competence Assessment .................................. 7 A.2 Candidate pre-requisites for the Blaster-Sprayer Competence Assessment ................ 7 A.3 Physical and stressful demands of the Competence Assessment ................................ 8 A.4 Aim and objectives of the Blaster-Sprayer Competence Assessment .......................... 9 A.5 Competence Assessment Outcomes ........................................................................... 9 A.6 Candidate Competence Assessment process .............................................................10 A.7 Duration and timing of the Competence Assessment ..................................................11 A.8 The Blaster-Sprayer Competence Units ......................................................................11

SECTION B Competence Reassessment ..........................................................................22

SECTION C Centre Resources ...........................................................................................23

C.1 Location of Assessment ..............................................................................................23 C.2 Staff ............................................................................................................................24 C.3 Facilities ......................................................................................................................25 C.4 Equipment (Materials) .................................................................................................25

SECTION D Administration and Certification ...................................................................26

D.1 Joining Instructions .....................................................................................................26 D.2 Periodicity ...................................................................................................................26 D.3 Certification .................................................................................................................26 D.4 Administration .............................................................................................................27

Glossary of terms and abbreviations ....................................................................................28

Appendix 1 Assessor Checklists ..........................................................................................29

Appendix 2 Candidate’s Assessment Record .......................................................................49


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Introduction

Industrial Blaster-Painters and Blaster-Sprayers continually use high energy and hazardous equipment in their daily work, therefore industry and regulators require that they undergo appropriate training and are competent to operate the blasting and paint spray equipment safely. Industry required that the training and competence assessment programmes are standardised to ensure consistency and quality. To this end OPITO, assisted by industry experts, has developed the Blaster-Painter Training standard and also the Blaster-Sprayer competence assessment standard. This standard comprises the Competence Assessment Programme for Blaster-Sprayer candidates and for experienced Blaster-Sprayers to demonstrate a minimum level of competence in the role, with successful candidates becoming OPITO-certified competent Blaster-Sprayers. It must be noted that new blasting and paint spraying equipment is being developed and entering the marketplace on a regular basis, so it is important that Blaster-Sprayer employers and operatives ensure that adequate training and familiarisation of new equipment is undertaken. The flow chart on the next page illustrates the routes required to achieve OPITO training and competence certification.

http://www.opito.com/media/downloads/trainee-blaster-painter-training.pdf


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Yes

Yes

Yes

Key:

Starting point for

training and

competence route

Decision

Employee nominated by company for further

development

Employee has evidence of appropriate experience as

Blaster/Painter

Person self sponsors to become a

Blaster/Painter

Employee deemed ready for assessment

by employer

Delegate undertakes Blaster/Painter Training at OPITO-approved training

site(See OPITO

Blaster/Painter Training Standard)

Delegatesuccessfully

completes training

Delegate cannot progress to the next stage without successfully completing the OPITO training programme.

Delegate awarded OPITO approved certificate and

deemed a Level 1 Blaster/Painter

Employer sponsored Level 1 B/P transfers to worksite for workplace experience -

recorded in log book

Level1 Candidates assessed against OPITO

Blaster/Sprayer Competence Standard

Candidate successful

Candidate becomes an OPITO-certified

Blaster/Sprayer (Level 2) to OPITO Standard

'Candidate' completes appropriate remedial

programme.

Level 1 B/P completes log book and deemed ready for Level 2 assessment

No

Yes

No

Self sponsored Blaster/Painters with experience but no

verifiable evidence of workplace experience

Undergoes a pre-assessment training

course. Training provider will

decide whether candidate is deemed ready for

assessment

Candidate deemed ready for assessment

Further training required

No

Further training and experience required

No


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SECTION A The Blaster-Sprayer Competence Assessment

A.1 Target Group for the Blaster-Sprayer Competence Assessment

The target groups for the Blaster-Sprayer Competence Assessment are personnel who wish to become OPITO-certified competent Blaster-Sprayers, having already completed their OPITO Initial Training and/or already have sufficient workplace experience in industrial blasting and painting activities.

A.2 Candidate pre-requisites for the Blaster-Sprayer Competence

Assessment

Candidate prerequisites for undertaking the Competence Assessment are:

(a) A valid OPITO-approved Blaster-Sprayer Training Certificate (Level-1) and a fully completed OPITO–approved logbook

Or (b) Verifiable evidence of Blaster-Sprayer experience.

Note: It is important that in both cases (a) and (b) specified above, the candidate should be ready to be assessed against the criteria specified in this standard; to that end, OPITO-approved assessment centres must ensure that candidates and candidate’s employers (if being sponsored by an employer) are fully aware of the standard criteria candidates will be assessed against – this would typically form part of the centre’s joining instructions.


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A.3 Physical and stressful demands of the Competence Assessment

Training and/or assessment activities contained within this Standard may include physically demanding and potentially stressful elements. All personnel who participate in such activities must be physically and mentally capable of participating fully. OPITO-approved Centres are therefore required, as a minimum, to ensure that prior to participating in practical exercises the delegate or candidate provides written confirmation that they deem themselves physically and mentally capable of undertaking all aspects of the training or assessment. Centres must also make the delegate/candidate aware that they must immediately inform the Centre staff if this capability changes – at any time prior to, or during the programme. Delegates/candidates must be advised that they are required to declare any current or pre-existing medical conditions which may be exacerbated by, or impair their ability to complete, the training/assessment programme. Should this be the case, the individual may be required to provide an authentic medical certificate issued since any identified medical condition was diagnosed. The OPITO-approved Centre shall keep a record of the delegate’s/candidate’s declaration of fitness in accordance with their document control policy(s) or procedures. This information, along with summary details of the type of physical activities the delegate/candidate will be asked to perform, will be given to delegates/candidates by the OPITO-approved Centre and, if applicable, to their sponsoring company as part of the joining instructions. The responsibility for declaring any known current or pre-existing medical conditions that could have adverse effects to the individual’s state of health while undertaking the training and/or assessment activities lies with the delegate/candidate and/or company sponsoring the delegate/candidate. Where doubt exists regarding the fitness of any delegate/candidate, the OPITO-approved Centre should direct the individual to consult a medical officer familiar with the nature and extent of the training. Note: Practical exercises should be designed and delivered solely to meet this Standard, and must not place on the delegates/candidates any physical or mental demands other than those required to meet the Standard.


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A.4 Aim and objectives of the Blaster-Sprayer Competence Assessment

The aim and objectives of the Blaster-Sprayer Competence Assessment are: to ensure that before newly trained candidates undertake unsupervised Blaster-Sprayer activities in the workplace, the performance skills and underpinning knowledge and understanding of the candidates are assessed by a qualified assessor against (and meet) the competence requirements specified in this OPITO Industry Standard. Also, experienced Blaster-Sprayers can gain industry-approved OPITO competence certification by successfully completing this Competence Assessment Programme.

A.5 Competence Assessment Outcomes

The assessment outcomes are specified in the Performance and Underpinning Knowledge and Understanding Criteria of the Competence Units in Section A8 of this Standard.


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A.6 Candidate Competence Assessment process

The candidate must be assessed by a suitably qualified assessor; refer to Section C.2 for assessor requirements. Section A.8 contains the Competence Assessment Criteria. A successful candidate must meet all the Assessment Criteria. Assessment Centres to assess candidates knowledge and understanding by using a combination of written questions, verbal questioning, and inferred underpinning knowledge & understanding by observation. Note: The candidate can be supported verbally with the understanding of the questions (without leading the candidate) by the Assessor or Invigilator, but the written test must be a ‘closed book’ format. The OPITO certificate of competence will be awarded to the successful candidate. The successful candidate i.e. the candidate that fully meets the knowledge and practical assessment standard will then be deemed *competent to undertake Blaster-Sprayer activities in the workplace. *It is the responsibility of the Blaster-Sprayer’s employer to ensure that the successful candidate is also competent to undertake any Blaster-Sprayer activities not covered within this Standard. Where a candidate does not meet the required assessment outcomes:

1. The assessor must clearly identify and record the outcomes which have not been met, and suggest any further training requirement. The Assessment Centre must provide the candidate (and the candidate’s employer – if applicable) with a written report identifying why the candidate was unsuccessful and suggest any further training requirement – within 7 days of the assessment.

2. No certificate will be awarded and the candidate must retake the assessment to gain an

OPITO competence certificate The OPITO-approved Training & Assessment Centre must confirm that the candidate is eligible to undertake the Blaster-Sprayer Assessment i.e. checking that the candidate has the appropriate prerequisites. The Assessment Centre must also ensure that:

(a) The candidate is briefed prior to the assessment, to ensure he/she knows how the

assessment will be conducted and what is expected of him/her during the assessment.

(b) The assessor provides feedback to the candidate following completion of the

practical assessments.


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Assessor/Candidate Ratio The maximum number of candidates undertaking the practical assessment is 6 The minimum number of candidates undertaking the practical assessment is 2 The assessor-to-candidate ratio is 1:3 (Note: even though more than one candidate may be assessed within the group of candidates during group-related activities, the assessor can only fully assess one candidate at a time)

A.7 Duration and timing of the Competence Assessment

The expected duration for the assessment is: 2 days (16 hours) for a group of 6 candidates.

A.8 The Blaster-Sprayer Competence Units

The following is the list of Units and Elements that the candidate will be assessment against:

Unit 1 Contribute to effective work activities

Element 1.1 Contribute to effective work activities

Unit 2 Contribute to health, safety and environmental quality

Element 2.1 Maintain health and safety practices in the workplace Element 2.2 Protect third party personnel, adjacent surfaces and the environment

Unit 3 Operate compressor equipment

Element 3.1 Operate compressor equipment

Unit 4 Prepare surfaces

Element 4.1 Degrease and clean surfaces, and use power tools Element 4.2 Clean surfaces using abrasive blasting

Unit 5 Apply coatings

Element 5.1 Prepare the work area and materials, including appropriate tests Element 5.2 Apply coatings with brush and roller Element 5.3 Apply coatings with paint sprayers

Continued.


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The Blaster-Sprayer Competence Units Criteria.

UNIT 1 Contribute to effective work activities

This Unit is about interpreting information and developing good working relationships.

Element 1.1 Contribute to effective work activities

Performance Criteria The candidate must demonstrate the following:

1.1.1 An understanding of the main elements of typical: permits, client safe systems of work, company procedures and risk assessments.

1.1.2 Interpreting MTDSs, client specifications and to decide on the appropriate blasting or coating method.

1.1.3 Conduct work according to a work pack with associated procedures and risk assessments.

1.1.4 How to contribute to a Tool Box Talk (TBT) 1.1.5 Ability to work within a team. 1.1.6 Correct storage of equipment after use.

Underpinning knowledge and Understanding

The candidate must demonstrate knowledge and understanding of the following:

1.1.7 How to obtain relevant operational policies, procedures, instructions, codes of

practice and standards. 1.1.8 Typical workplace reporting procedures relevant to the Blaster-Sprayer. 1.1.9 How to get specific information required for project records. 1.1.10 Explain how Blaster-Sprayers typically request equipment, materials and PPE

from a work scope.

Unit Element Scope: Others; to include one or more of the following: co-workers, supervisors, and other company employees, and visitors. Situations; to include one or more of the following: informal meetings, formal meetings, normal work situations, team briefings and handovers.


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UNIT 2 Contribute to health, safety and environmental quality

This unit is about working in a safe manner with due regard for the environment.

Element 2.1 Maintain health and safety practices in the workshop

Performance Criteria The candidate must demonstrate the following:

2.1.1 Ensure that personal protective equipment (PPE) is available for use, in good repair and appropriately used.

2.1.2 Ensure tools/equipment are within specification and certification dates. 2.1.3 Record exposure time for HAVS records. 2.1.4 Safely, transfer tools, paint and equipment to the work area and return on

completion of work to the storage area using relevant manual handling techniques.

2.1.5 Keep the work area as clean and tidy as possible. 2.1.6 Identify and report unsafe equipment. 2.1.7 Work safely in accordance with operational requirements and associated safe

systems of work.


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Element 2.1 Maintain health and safety practices in the workshop. Continued. Underpinning knowledge and Understanding

The candidate must demonstrate knowledge and understanding of the following

2.1.8 Typical sources of safety information and safety observation systems of a

site/ installation. 2.1.9 How to interpret a basic task-based risk assessment. 2.1.10 The use and care of various types of PPE & RPE related to Blaster-Sprayer

operations. 2.1.11 Awareness of RPE tests and how often they should be done. 2.1.12 Typical hazards for blasting/painting activities. 2.1.13 The consequences of faulty or disconnected ‘dead man’ units. 2.1.14 How and when to connect anti-static earth lines. 2.1.15 Typical precautions to take for working on live lines*. 2.1.16 Relevant elements of COSHH Assessment and how to interpret key points of

a MSDS. 2.1.17 Appropriate communications methods when working as part of a team 2.1.18 Typical problems associated with HAVS and the importance of recording

exposure times. 2.1.19 Use of safe access equipment and platforms, and the ‘Scafftag’ system. 2.1.20 Typical manual handling hazards and how mechanical lifting and handling

aids can be used to overcome these. 2.1.21 Typical hazards associated with Blaster-Sprayer operations in confined

spaces. 2.1.22 Typical methods for controlling Blaster-Sprayer-related risks in confined

spaces. 2.1.23 Maintaining an emergency escape route from the work area. 2.1.24 What to do if an unsafe act/s was observed by the Blaster-Sprayer.

*Live lines could include: pressurised pipework or vessels, high temperature pipework or vessels and pipework or vessels containing hazardous fluids. Scope: PPE; items must be chosen in accordance with risk assessments and company procedures. Safe systems of work to include processes that incorporate hazard identification, risk assessment and Permit-to-Work systems.


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Element 2.2 Protect third party personnel, adjacent surfaces and the environment Performance Criteria The candidate must demonstrate the following:

2.2.1 Protect* adjacent surfaces, plant and equipment not being blast-cleaned or coated.

2.2.2 Protect prepared or painted work surfaces. 2.2.3 Limit access to the area with appropriate signs and barriers. 2.2.4 Ensure waste is limited by correctly following instructions for mixing ratios.


The candidate must demonstrate knowledge and understanding of the following: 2.2.5 How to develop a spill plan, locate and position spill containers. 2.2.6 How to limit dust, debris and hazardous material from contaminating the

environment and harming personnel. 2.2.7 How to contain spray painting or blasting during windy conditions. 2.2.8 How to ensure waste is limited by re-using masking materials – where

possible.

*Protect adjacent surfaces; to include masking up, using polythene sheets or building a habitat in which to work.


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UNIT 3 Operate compressor equipment Element 3.1 Operate compressor equipment Performance Criteria The candidate must demonstrate the following:

3.1.1 Completing compressor familiarisation, pre-start checks and correctly connecting relevant equipment for the work.

3.1.2 Checking area in proximity of compressor air intake is clear. 3.1.3 Checking for foreign objects in the compressor case. 3.1.4 Correctly start up the compressor following relevant instructions or

procedures. 3.1.5 Monitor compressor to ensure it is functioning properly during abrasive

blasting or spray painting. 3.1.6 Shutting down compressor correctly and completing post-stop checks.


The candidate must demonstrate knowledge and understanding of the following: 3.1.7 Awareness of the different types of compressors applicable to Blaster-

Sprayer operations and their applications. 3.1.8 Typical protection devices fitted to compressors. 3.1.9 How to shut down the compressor in an emergency. 3.1.10 The purpose and use of pre-start up checks. 3.1.11 Typical hazards and precautions associated with multiple users sharing the

same compressor. 3.1.12 Actions to be taken in the event of faults arising on the compressor.

Scope: Procedures; to include manufacturers and/or typical company and client procedures. Equipment; to include blasting equipment, “dead man” handle, blast nozzles, blast helmets, airlines and compressor.


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UNIT 4 Prepare surfaces This unit is about the preparation of surfaces for coating, including cleaning by hand using power tools and abrasive blasting.

Element 4.1 Degrease and clean surfaces, and correct use power tools Performance Criteria The candidate must demonstrate the following:

4.1.1 Identify and correctly don appropriate PPE for mechanical preparation tasks. 4.1.2 Degrease and clean surfaces in accordance with work pack* guidelines and

procedures. 4.1.3 Correct use of mechanical power tools for surface preparation.

*Work pack: Assessment Centre to provide work pack for assessment.


The candidate must demonstrate knowledge and understanding of the following: 4.1.4 Reasons for correctly preparing a surface. 4.1.5 The types of surfaces commonly treated by industrial Blaster-Sprayers. 4.1.6 The purpose of surface pre-cleaning the surface prior to conducting surface

preparation. 4.1.7 The consequences of applying coating to a surface that has not been

correctly prepared.

Scope: Surface preparation mechanical power tools; must include items from the following range: needle gun, air sander, bristle blaster and air power wire brush.


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Element 4.2 Prepare surfaces using abrasive blasting Performance Criteria The candidate must demonstrate the following:

4.2.1 Identify appropriate PPE for specific Blaster-Sprayer tasks. 4.2.2 Correctly don PPE and ensure respiratory equipment is functional. 4.2.3 Install tear-offs on the blast hood. 4.2.4 Check equipment is in safe working order. 4.2.5 Load, monitor and maintain the supply of abrasive during the project. 4.2.6 Assemble blasting equipment correctly. 4.2.7 Monitor the air supply for any malfunction. 4.2.8 Use the appropriate technique to blast identified surfaces. 4.2.9 Ensure the visual surface preparation and blast profile are checked at agreed

‘hold points’. 4.2.10 Contain spent materials in a safe and secure manner. 4.2.11 Ensure that cleaned surfaces are to the required standard. 4.2.12 Shutdown and make safe the blasting equipment. 4.2.13 Transfer used waste materials to the appropriate disposal site. 4.2.14 Reinstate the worksite in accordance with operation’s requirements.


The candidate must demonstrate knowledge and understanding of the following:

4.2.15 The importance of pre-shift checks of all blasting equipment for signs of

deterioration or damage, to include: hoses, lines, joints and dead man handles.

4.2.16 Factors affecting air quality supplied to blasting equipment and breathing air supplied to hoods.

4.2.17 The differences between dry grit blasting and wet slurry blasting. 4.2.18 Typical pressure-relief systems and components associated with blasting

equipment. 4.2.19 Typical quality control checks on surfaces that have been abrasive blasted. 4.2.20 The consequences and control of flash rusting in the case of wet slurry

blasting.

Element 4.2 Scope: Blasting equipment; to include equipment for dry grit blasting or wet slurry blasting.


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UNIT 5 Apply Coatings This unit is about the coating the surfaces with paint using appropriate equipment, materials and techniques.

Element 5.1 Prepare the work area and materials including appropriate tests Performance Criteria The candidate must demonstrate the following:

5.1.1 Conduct visual checks of work surfaces for contamination and defects; to include checks for runs, sags, grit inclusion and overspray.

5.1.2 Prepare coatings to client specification by following the manufacturer’s instructions.

5.1.3 Select and correct spray tip size needed for spraying different materials and surfaces.

5.1.4 Allow for the correct time between further coatings.


The candidate must demonstrate knowledge and understanding of the following: 5.1.5 Typical types of coatings, to include: batch numbers and shelf life of the

coatings. 5.1.6 Actions to take if experiencing unacceptable variations in environmental

conditions. 5.1.7 The effects of working outside acceptable variations in environmental

conditions. 5.1.8 Time allowance between coats. 5.1.9 Symptoms causes and corrections of common coating failures.


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Element 5.2 Apply coatings with brush (and roller when appropriate) Performance Criteria The candidate must demonstrate the following:

5.2.1 Identify and don appropriate PPE for specific hand painting application tasks. 5.2.2 Use the appropriate technique to stripe coat surfaces using a brush. 5.2.3 Use the appropriate technique to apply the coating using a brush and/or

roller. 5.2.4 Ensure that coated surfaces are acceptable to the supervisor/inspector. 5.2.5 Check wet film thickness using a wet film gauge. 5.2.6 How to clean and store paint brushes and rollers.


The candidate must demonstrate knowledge and understanding of the following: 5.2.7 Types of paint brushes/rollers and selecting the correct type for the

application. 5.2.8 The reasons for stripe coating effectively. 5.2.9 The purpose of conducting wet film thickness checks during application. 5.2.10 How to clean and store paint brushes and rollers.

Scope: Surfaces; to include: broad areas, angled areas, linear items and complex shapes.


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Element 5.3 Apply coatings with spray paint Performance Criteria The candidate must demonstrate the following:

5.3.1 Don appropriate PPE and ensure respiratory equipment is functional. 5.3.2 Select the appropriate paint spraying equipment (including correct spray tip),

for the task and ensure that it conforms to specific job requirements. 5.3.3 Identify the coatings suitable for the task. 5.3.4 Correctly assemble paint spraying equipment. 5.3.5 Correctly mix the paint. 5.3.6 Conduct checks on paint spraying equipment, compressed air equipment and

pressurised lines to ensure they are in safe working order. 5.3.7 Monitor the hood and spray equipment air supplies and take appropriate

action on any malfunction. 5.3.8 Load, monitor and maintain the supply of paint during operations. 5.3.9 Use the appropriate technique to spray surfaces to meet specifications. 5.3.10 Check wet film thickness using a wet film gauge. 5.3.11 Ensure that coated surfaces are acceptable to the supervisor/inspector. 5.3.12 Correct method of cleaning, shutting down and making safe the paint

spraying equipment.


The candidate must demonstrate knowledge and understanding of the following: 5.3.13 The main differences between hood lines and paint spray lines. 5.3.14 Methods for applying non-slip coatings. 5.3.15 How to check wet film thickness during application. 5.3.16 The purpose of surface cleanliness checks and how to perform them. 5.3.17 How to report defects and faults in equipment. 5.3.18 The consequences of not flushing out paint spray lines properly. 5.3.19 Awareness of other types of spraying equipment. 5.3.20 Hold points, and when to get sprayed coats checked.

Scope: Paint spraying equipment; to include airless spray units. Surfaces; to include broad areas, angled areas, linear items and complex shapes.


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SECTION B Competence Reassessment

For Blaster-Sprayers to maintain their OPITO competence certification, they must be reassessed against the competence units specified in Section A8 within four years of successfully completing their initial assessment.


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SECTION C Centre Resources

C.1 Location of Assessment

It is recognised that certain elements of competence assessment can be more robust when carried out ‘on-the-job’. Accordingly, this Standard has been deemed suitable for ‘on-location’ assessment. However, prior to any such assessments taking place, OPITO-Approved Training & Assessment Centres must comply with the following requirements:

(a) Prior to initial approval, the Training & Assessment Centre will specify a single onshore ‘approved site’ and advise OPITO of its intention to carry out assessments remotely, i.e. ‘on-location’.

(b) Prior to initial approval, the Training & Assessment Centre will advise OPITO where all their remote assessments are expected to take place. After approval is awarded, any additional locations must be communicated to OPITO as and when they arise.

(c) The Training & Assessment Centre shall ensure the suitability of ‘on-location’ facilities and arrangements prior to each assessment.

(d) Documented evidence will be retained to show that assessment at the remote site meets the criteria detailed in this OPITO standard including, but not limited to, facilities, equipment and qualifications of relevant staff (see Section C2).

(e) Documented evidence shall be retained that record all measures required to assure the quality and safety of ‘on-location’ assessment activities.

(f) All records must be retained at the single onshore ‘approved site’ (see Point (a) above).

(g) OPITO reserves the right to audit any or all of the remote sites operated by the Training & Assessment Centre at any time


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C.2 Staff

In order that an assessment programme may be delivered successfully it is essential that the right people are in place to support the programme. OPITO-approved assessment centres must ensure that assessors are competent and qualified to conduct the assessment of candidates undertaking the Blaster-Sprayer Assessments. Assessor Requirements Assessors must:

(a) Be occupationally competent i.e. they must have had relevant experience in the

blaster/painter/sprayer role and hold: I. *a valid OPITO Blaster-Sprayer competence certificate,

or II. An equivalent relevant qualification or certification (e.g. a NACE-level 3

certificate).

(b) Hold an industry-recognised assessor’s qualification e.g. A1, D33, L20, the

OPITO-approved Competence Assessor Certificate, or equivalent qualification. (c) Fully understand the OPITO-approved Assessment Centre’s internal quality

assurance of assessment processes and practices. (d) Fully understand the requirements of this Industry Standard. (e) Fully understand the OPITO requirements for recording assessment decisions

and securely maintaining accurate records of these. (f) Participate in regular standardisation meetings or events to ensure a consistent

approach to assessment. (g) Undertake and record continuing professional development (CPD).

* Contact OPITO’s Standards & Approvals Manager for guidance on this requirement.


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C.3 Facilities

OPITO-approved Assessment Centres must, as a minimum, comply with the following:

Administration arrangements must be made available to support candidates through the assessment process.

Practical assessments must be planned in advance to ensure that all the candidates get an equal opportunity to demonstrate their Blaster-Sprayer skills - as specified in this Standard. All facilities must be maintained and where appropriate, inspected and tested in accordance with current standards/legislation. First Aid Facilities Appropriate first aid facilities and equipment as specified in the training centre’s risk assessments, and sufficient staff, trained in the use of the facilities and equipment.

C.4 Equipment (Materials)

As a minimum, the following equipment is required to meet the stated content of the assessment:

1. Appropriate PPE e.g. safety helmets, safety boots, eye protection, hearing protection, gauntlets, blast suits, air-fed masks, vapour masks, gloves and blast helmets. Also high-visibility vests for candidates/assessors

2. Blasting equipment (dry-grit or wet slurry); to include ‘dead man’s handles’, blast nozzles and associated airlines

3. Airless paint spraying equipment 4. Mechanical power tools; to include a needle gun, air sander, bristle blaster and air power

wire brush 5. A range of surfaces to prepare and paint; to include broad areas, angled areas, linear

items or complex shapes 6. Industry recognised surface profile comparator gauges. 7. Work Pack, to include guidance and procedures for blasting, painting and spraying*.

* Note: Candidate must be allowed sufficient time to familiarise themselves with the work pack details. All equipment must be maintained and inspected and tested in accordance with applicable legislation and standards. Certificates and maintenance schedules should be available at all times. The OPITO-approved assessment centre must undertake and record risk assessments for all assessment activities.


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SECTION D Administration and Certification

D.1 Joining Instructions

The OPITO-approved Assessment Centre must provide the candidate either with a copy of the OPITO-approved Blaster-Sprayer Competence Assessment Standard or a link to the Standard on the OPITO website - so that the candidate can make himself/herself aware of the requirements of the Standard.

D.2 Periodicity

The Certificate is valid for 4 years. Therefore Blaster-Sprayers that wish to maintain their OPITO competence certification must be assessed as meeting this standard every 4 years.

D.3 Certification

Candidates successfully meeting the OPITO-approved Blaster-Sprayer Competence Assessment Standard will be issued with an OPITO certificate of competence. The issue of the certificate indicates that the candidate has achieved the level of competence as defined by oil and gas industry employers under a process approved by OPITO. The details of each candidate will be updated on Vantage, the industry’s central recording data base. OPITO-approved Centres are responsible for issuing a certificate direct to candidates that have successfully completed Competence Assessment, and to the sponsoring company - when required. Each certificate must indicate that the candidate has met the requirements of the OPITO Competence Assessment Standard. The certificate must also contain the following:

(a) OPITO-approved Centre name (b) Full OPITO course/assessment title stating that it is OPITO-approved (c) OPITO registration code (d) Candidate’s name (e) Course/assessment dates (f) Certificate expiry date (g) Unique Certificate Number (refer to guide on OPITO website) (h) OPITO-approved Centre Signatory.

http://www.opito.com/content/approvals-faqs


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D.4 Administration

Each candidate undertaking any OPITO-approved assessment programme must be registered with the Central Register (CR) operated by OPITO. Registration must be made by the training establishment to OPITO within one week following the assessment programme. OPITO confirms that information on the registration form will be contained in a computerised register which will be available to employers, prospective employers and training providers in the oil and gas industry to verify training records. At all times use of this data will be strictly in accordance with principles laid down in applicable data protection legislation.


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Glossary of terms and abbreviations

Terms ScaffTag Industry-standard scaffold status tagging system to help prevent working at

height hazards and efficiently manage inspection procedures. It uses a unique holder and insert system to ensure the latest status of scaffolding is instantly visible at the point of use.

Hold points A predetermined stopping point for the work process to ensure the work is

checked or inspected before proceeding. Invigilator A person nominated by the OPITIO-approved Centre to oversee the written test

and ensure that no cheating takes place. But, also to assist and support the candidates taking the test with any special needs.

Abbreviations COSHH Control of Substances Hazardous to Health HAVS Hand and Arm Vibration Syndrome MSDS Material Safety Data Sheet MTDS Manufacturers’ Technical Data Sheet PPE Personal Protective Equipment PTW Permit to Work RPE Respiratory Protection Equipment WAH Working at Height


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Appendix 1 Assessor Checklists

ASSESSORS’ CHECKLISTS

Unit 1 Contribute to effective work activities

Element 1.1 Contribute to effective work activities: Performance Criteria

Ref: Task Completed Source of Evidence

1.1.1 An understanding of the main elements of typical: permits, client safe systems of work, company procedures and risk assessments

1.1.2 Interpreting MTDSs, client specifications and to decide on the appropriate blasting or coating method

1.1.3 Conduct work according to a work pack with associated procedures and risk assessments

1.1.4 How to contribute to a Tool Box Talk (TBT)

1.1.5 Ability to work within a team

1.1.6 Correct storage of equipment after use

Scope: Others to include one or more of the following: co-workers, supervisors, and other company employees, and visitors. Situations to include one or more of the following: informal meetings, formal meetings, normal work situations, team briefings and handovers

Assessor Comments:

Source of Evidence O - Observation S - Simulation Q – Verbal Questioning W – written question I - Inferred

Assessor: Name:_________________ Signature: __________ ___ Date:___/___/___ Candidate Name: :_________________ ________


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Unit 1 Contribute to effective working relationships

Element 1.1 Contribute to effective work activities: Knowledge & Understanding

Ref: Criteria Completed Source of Evidence

1.1.7 How to obtain relevant operational policies, procedures, instructions, codes of practice and standards

1.1.8 Typical workplace reporting procedures relevant to the Blaster-Sprayer

1.1.9 How to get specific information required for project records.

1.1.10 Explain how Blaster-Sprayers typically request equipment, materials and PPE from a work scope.

Assessor Comments:




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Unit 2 Contribute to health, safety and environmental control

Element 2.1 Maintain health and safety practices in the workshop: Performance Criteria


2.1.1 Ensure that personal protective equipment (PPE) is available for use, in good repair and appropriately used.

2.1.2 Ensure tools/equipment are within specification and certification dates

2.1.3 Record exposure time for HAVS records

2.1.4 Safely, transfer tools, paint and equipment to the work area and return on completion of work to the storage area using relevant manual handling techniques

2.1.5 Keep the work area as clean and tidy as possible

2.1.6 Identify and report unsafe equipment

2.1.7 Work safely in accordance with operational requirements and associated safe systems of work

Scope: PPE items must be chosen in accordance with risk assessments and company procedures Dangerous occurrences: Blaster-Sprayer has right & duty to intervene if they felt a situation or process was unsafe Safe systems of work to include processes that incorporate hazard identification, risk assessment and Permit to Work systems

Assessor Comments:




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Element 2.1 Maintain health and safety practices in the workshop: Knowledge & Understanding


2.1.8 Typical sources of safety information and safety observation systems of a site/ installation

2.1.9 How to interpret a basic task-based risk assessment

2.1.10 The use and care of various types of PPE & RPE related to Blaster-Sprayer operations

2.1.11 Awareness of RPE tests and how often they should be done

2.1.12 Typical hazards for blasting/painting activities

2.1.13 The consequences of faulty or disconnected ‘dead man’ units

2.1.14 How and when to connect anti-static earth lines

2.1.15 Typical precautions to take for working on live lines*

2.1.16 Relevant elements of COSHH Assessment and how to interpret key points of a MSDS

2.1.17 Appropriate communications methods when working as part of a team

2.1.18 Typical problems associated with HAVS and the importance of recording exposure times

2.1.19 Use of safe access equipment and platforms, and the ‘Scafftag’ system

2.1.20 Typical manual handling hazards and how mechanical lifting and handling aids can be used to overcome these

2.1.21 Typical hazards associated with Blaster-Sprayer operations in confined spaces

2.1.22 Typical methods for controlling Blaster-Sprayer-related risks in confined spaces

2.1.23 Maintaining an emergency escape route from the work area

2.1.24 What to do if an unsafe act/s was observed by the Blaster-Sprayer


Element 2.1 Maintain health and safety practices in the workshop: Knowledge and Understanding


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Assessor Comments:




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Unit 2 Contribute to health, safety & environmental quality

Element 2.2 Protect third party personnel, adjacent surfaces and the environment: Performance Criteria


2.2.1 Protect* adjacent surfaces, plant and equipment not being sand-cleaned or coated

2.2.2 Protect prepared or painted work surfaces

2.2.3 Limit access to the area with appropriate signs and barriers

2.2.4 Ensure waste is limited by correctly following instructions for mixing ratios

*Protect adjacent surfaces; to include masking up, using polythene sheets or building a habitat in which to work

Assessor Comments:




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Unit 2 Contribute to health, safety and environmental quality

Element 2.2 Protect third party personnel, adjacent surfaces and the environment: Knowledge & Understanding: Criteria


2.2.5 How to develop a spill plan, locate and position spill containers

2.2.6 How to limit dust, debris and hazardous material from contaminating the environment and harming personnel

2.2.7 How to contain spray painting or blasting during windy conditions

2.2.8 How to ensure waste is limited by re-using masking materials

Scope:

Assessor Comments:




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Element 3.1 Operate compressor equipment: Performance Criteria


3.1.1 Completing compressor familiarisation, pre-start checks and correctly connecting relevant equipment for the work

3.1.2 Checking area in proximity of compressor air intake is clear

3.1.3 Checking for foreign objects in the compressor case

3.1.4 Correctly start up the compressor following relevant instructions or procedures

3.1.5 Monitor compressor to ensure it is functioning properly during abrasive blasting or spray painting

3.1.6 Shutting down compressor correctly and completing post-stop checks

Scope:

Procedures; to include manufacturers and/or typical company and client procedures

Equipment; to include blasting equipment, “dead man” handle, blast nozzles, blast helmets, airlines and compressor

Assessor Comments:




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Element 3.1 Operate compressor equipment: Knowledge & Understanding


3.1.6 Awareness of the different types of compressors applicable to Blaster-Sprayer operations and their applications

3.1.7 Typical protection devices fitted to compressors

3.1.8 How to shut down the compressor in an emergency

3.1.9 The purpose and use of pre-start up checks

3.1.10 Typical hazards and precautions associated with multiple users sharing the same compressor

3.1.11 Actions to be taken in the event of faults arising on the compressor

Assessor Comments:




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Element 4.1 Degrease and clean surfaces, and use correct power tools: Performance Criteria


4.1.1 Identify and correctly don appropriate PPE for mechanical preparation tasks

4.1.2 Degrease and clean surfaces in accordance with work pack* guidelines and procedures

4.1.3 Correct use of mechanical power tools for surface preparation

*Work pack: Assessment Centre to provide work pack for assessment. Scope: Surface preparation mechanical power tools; must include items from the following range: needle gun, air sander, bristle blaster and air power wire brush.

Assessor Comments:




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Element 4.1 Degrease and clean surfaces, and use correct power tools: Knowledge & Understanding


4.1.4 Reasons for correctly preparing a surface

4.1.5 The types of surfaces commonly treated by industrial Blaster-Sprayers

4.1.6 The purpose of pre-cleaning the surface prior to conducting surface preparation.

4.1.7 The consequences of applying coating to a surface that has not been correctly prepared.

Assessor Comments:




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Element 4.2 Prepare surfaces using abrasive blasting: Performance Criteria


4.2.1 Identify appropriate PPE for specific Blaster-Sprayer tasks

4.2.2 Correctly don PPE and ensure respiratory equipment is functional

4.2.3 Install tear-offs on the blast hood

4.2.4 Check equipment is in safe working order

4.2.5 Load, monitor and maintain the supply of abrasive during the project

4.2.6 Assemble blasting equipment correctly

4.2.7 Monitor the air supply for any malfunction

4.2.8 Use the appropriate technique to blast identified surfaces

4.2.9 Ensure the visual surface preparation and blast profile are checked at agreed ‘hold points’

4.2.10 Contain spent materials in a safe and secure manner

4.2.11 Ensure that cleaned surfaces are to the required standard

4.2.12 Shut down and make safe the blasting equipment

4.2.13 Transfer used waste materials to the appropriate disposal site

4.2.14 Reinstate the worksite in accordance with operation’s requirements

Scope: Blasting equipment to include equipment for dry grit blasting or wet slurry blasting


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Continued…


Element 4.2 Prepare surfaces using abrasive blasting: Performance Criteria

Assessor Comments:




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Element 4.2 Prepare surfaces using abrasive blasting: Knowledge & Understanding


4.2.15 The importance of pre-shift checks of all blasting equipment for signs of deterioration or damage, to include: hoses, lines, joints and dead man handles

4.2.16 Factors affecting air quality supplied to blasting equipment and breathing air supplied to hoods

4.2.17 The differences between dry grit blasting and wet slurry blasting

4.2.18 Typical pressure-relief systems and components associated with blasting equipment

4.2.19 Typical quality control checks on surfaces that have been abrasive blasted

4.2.20 The consequences and control of flash rusting in the case of wet slurry blasting

Assessor Comments:




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Element 5.1 Prepare the work area and materials including appropriate tests: Performance Criteria


5.1.1 Conduct visual checks of work surfaces for contamination and defects; to include checks for runs, sags, grit inclusion and overspray

5.1.2 Prepare coatings to client specification by following the manufacturer’s instructions

5.1.3 Select and correct spray tip size needed for spraying different materials and surfaces

5.1.4 Allow for the correct time between further coatings

Assessor Comments:




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Element 5.1 Prepare the work area and materials including appropriate tests: Knowledge & Understanding


5.1.5 Typical types of coatings, to include: batch numbers and shelf life of the coatings

5.1.6 Actions to take if experiencing unacceptable variations in environmental conditions

5.1.7 The effects of working outside acceptable variations in environmental conditions

5.1.8 Time allowance between coats

5.1.9 Symptoms, causes and corrections of common coating failures

Assessor Comments:




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Element 5.2 Apply coatings with brush (and roller when appropriate): Performance Criteria


5.2.1 Identify and don appropriate PPE for specific hand painting application tasks

5.2.2 Use the appropriate technique to stripe coat surfaces using a brush

5.2.3 Use the appropriate technique to apply the coating using a brush and/or roller

5.2.4 Ensure that coated surfaces are acceptable to the supervisor/inspector

5.2.5 Check wet film thickness using a wet film gauge

5.2.6 How to clean and store paint brushes and rollers

Scope: Surfaces to include broad areas, angled areas, linear items and complex shapes

Assessor Comments:




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Element 5.1 Apply coatings with brush and roller: Knowledge & Understanding


5.2.7 Types of paint brushes/rollers and selecting the correct type for the application

5.2.8 The reasons for stripe coating effectively

5.2.9 The purpose of conducting wet film thickness during application

5.2.10 How to clean and store paint brushes and rollers

Scope: Surfaces to include broad areas, angled areas, linear items and complex shapes

Assessor Comments:




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Element 5.3 Apply coatings with spray paint: Performance Criteria


5.3.1 Don appropriate PPE and ensure respiratory equipment is functional

5.3.2 Select the appropriate paint spraying equipment (including correct spray tip), for the task and ensure that it conforms to specific job requirements

5.3.3 Identify the coatings suitable for the task

5.3.4 Correctly assemble paint spraying equipment

5.3.5 Correctly mix the paint

5.3.6 Conduct checks on paint spraying equipment, compressed air equipment and pressurised lines to ensure they are in safe working order

5.3.7 Monitor the hood and spray equipment air supplies and take appropriate action on any malfunction

5.3.8 Load, monitor and maintain the supply of paint during operations

5.3.9 Use the appropriate technique to spray surfaces to meet specifications

5.3.10 Check wet film thickness using a wet film gauge

5.3.11 Ensure that coated surfaces are acceptable to the supervisor/inspector

5.3.12 Correct method of cleaning, shutting down and making safe the paint spraying equipment

Scope: Paint spraying equipment: to include airless spray units Surfaces to include broad areas, angled areas, linear items and complex shapes

Assessor Comments:




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Element 5.3 Apply coatings with spray paint: Knowledge & Understanding


5.3.13 The main differences between hood lines and paint spray lines

5.3.14 Methods for applying non-slip coatings

5.3.15 How to check wet film thickness during application

5.3.16 The purpose of surface cleanliness checks and how to perform them

5.3.17 How to report defects and faults in equipment

5.3.18 The consequences of not flushing out paint spray lines properly

5.3.19 Awareness of other types of spraying equipment

5.3.20 Hold points, and when to get sprayed coats checked

Assessor Comments:




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Appendix 2 Candidate’s Assessment Record

OPITO Blaster-Sprayer Competence Assessment

Candidate full name

Company

Region

Assessor Declaration: The Candidate was assessed against the competence assessment criteria specified in this OPITO Blaster-Sprayer Competence Assessment Standard. The Candidate named above *has / has not achieved a level of competence to enable him/her to work as an industrial Blaster-Sprayer. *I recommend that the candidate named requires further training and development specified above. * delete as applicable

Recommended further training and development for candidate:

Assessor's Name Signature Date

OPITO Assessment Centre

Centre address

Candidate Signature Date

Note: Assessor and candidate must sign the Assessment Record above.

Documents

OPITO APPROVED STANDARD Blaster-Sprayer Competence Standard · OPITO Approved Standard Blaster-Sprayer ... workplace experience in industrial blasting and painting ... Approved Standard