Professional Documents
Culture Documents
Industry
REYES, JONATHAN P.
PAINTS
Today paints are used for colorings and protecting many
surfaces, including houses, cars, road markings and
underground storage vessels.
PAINTS
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.
C0MPOSITION
binders
pigments
Solvent
5. CUSTOMERS
ORDERS AND RAW
MATERIAL
2. CONTROLS
6. PRODUCTION
3. QUALITY OF
PROCEDURAL
PROBLEMS
4. PERSONNEL
AND TRAINING
7. PACKAGING
8. WAREHOUSING
9. QUALITY
CONTROL
1. OBJECTIVES
Good Manufacturing Practices are embodied in a Total Quality
Management System as described in the standards contained in the
ISO 9000 series to make possible the manufacture of surface coatings,
which the customer has ordered
an agreed quality
standard
requirements contained
in directives, legislation
and regulations
CLOSURE
2. CONTROL
MANUALS
Production
Instruction Document
2. CONTROL
Product Test
Specification
QUALITY MANAGER
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.
DEDICATION
TRAINING
Raw
Materials
Product
Delivery
Details
Materials
Required
Quantities
Required
Packaging
Details
Identification
Identification
Specification
Specification
Test Methods
Test Methods
Delivery Date
and Time
Conformity
Conformity
Delivery Point
Traceability
Price
Raw
Materials
Identification
Test Methods
These should be agreed by supplier and coating manufacturer. Where possible well
known, internationally and industry accepted methods of test and chemical analysis
should be used.
Traceability
Traceability of a batch of raw material is achieved by using the delivery/batch
reference numbers throughout the system.
Identification
Specification
Each coating has a detailed
specification, which in the case
of direct sale to a user
customer, has been agreed by
the coating manufacturer and
user.
Method of
Application
Solids Content,
Specific Gravity,
Viscosity
Curing Schedule
Film weight or
Thickness
Conformity
Every delivery of coating should be supported by a certificate of
conformity detailing the list of tests, which have been carried out with
the results to show that it meets the agreed specification.
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.
6. Production
The Formula and The Process
Manufacturing Instruction
Document
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.
The Formula
This only allows the use of approved raw
materials
in
the
quantities
and
proportions necessary to obtain the
quality of product required
6. Production
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
6. Production
Cleanliness
Written plant cleaning and inspection
procedures exist to ensure removal of
any undesired material from all
equipment prior to the manufacture of
the coating.
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 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 any contamination with another product
or foreign bodies
7. Packaging
Accurate Filling
When necessary, suitable controls should
be installed to ensure accurate filling.
Labeling
Each container for dispatch should carry labels
showing:
Agreed
Identification
Batch
Identification
Net Volume
Manufacturing
Date
Health and
Safety
Expiry Date
Gross/ Net
Weight
Quality
Approved
Instruction
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
Product
A procedure should exist to re-test stock if it is approaching its expiry date or may have
drifted out of specification, before dispatch to the customer
9. Quality Control
Objectives
To carry out laboratory test on raw materials, coatings in production and finished
coatings to ensure that the material to the customer is fit for use and conforms to
appropriate directives, legislation or regulations.
Raw
Materials
Production
Control
Finished
Product
Testing
Test
Equipment
LOCAL COMPANY:
LOCAL COMPANY:
PRODUCT
Boysen Philippines produces various types of paints ranging from waterbased coatings to epoxy-based coatings.
Latex Paint
or acrylic paint, a fast-drying paint containing pigment
suspension in acrylic polymer emulsion. It is usually used
for painting walls and ceilings, and most suitable for
painting concrete materials.
Enamel
Paint
LOCAL COMPANY:
Manufacturing Process
Raw Material
Binder
also called the vehicle, is the film-forming component of
paint. Boysen uses Titanium Dioxide (TiO2) as their
binder.
Solvent
dissolves the polymer and adjust the viscosity of the
paint. It is volatile and does not become part of the paint
film.
LOCAL COMPANY:
Manufacturing Process
Raw Material
Pigment
granular solids that are incorporated in the paint to
contribute color.
Additives
paint can have a wide variety of miscellaneous additives,
which are usually added in small amounts, yet provide a
significant effect on the product.
LOCAL COMPANY:
Manufacturing Process
PROCESS
Raw Materials
Preparation
Ingredients are measured by weight on scales, and in some cases by volume in
calibrated vats and graduated measuring containers.
LOCAL COMPANY:
Manufacturing Process
PROCESS
Pigment Dispersion
Pigments that tend to stick together to form clumps or agglomerates are broken
down into separate particles that must then be wetted by resin and additives to
stop them sticking together again.
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
LOCAL COMPANY:
Manufacturing Process
PROCESS
Laboratory Testing
The quality control engineer takes a sample from the batch and tests it in the
laboratory for pH, gloss, and viscosity analysis. This is where the batch is
rejected or accepted.
Canning
When testing is completed the batch is passed for canning. The batch is passed
for use in the warehouse and dispatch to branches as required.
LOCAL COMPANY:
LOCAL COMPANY:
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.
The plant is a strict smoke-free facility and a smoking
area for smoking employees is provided outside the
plant.
LOCAL COMPANY:
Warehousing
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.
Chemical Industry
REYES, JONATHAN P.
INTRODUCTION
An effective control of chemical risks at the workplace requires an efficient flow of
information from the manufacturers or importers to the users of chemicals on potential
hazards and on the safety precautions to be taken. This flow of information should be
followed by daily action by employers to ensure that the necessary measures are taken
to protect workers, and consequently the public and the environment.
OBJECTIVE
1
GUIDELINES
Ensuring that all chemicals including impurities, by-products and intermediates, and
wastes that may be formed, are evaluated to determine their hazards;
Ensuring that employers are provided with a mechanism for obtaining from their
suppliers information about the chemicals used at work to enable them to implement
effective programs to protect workers from chemical hazards;
Providing workers with information about the chemicals at their workplaces and about
appropriate preventive measures to enable them to participate effectively in safety
programs
Establishing principles for such programmers to ensure that chemicals are used and
produced safely;
Making special provision to protect confidential information
Types
Advantages
Natural Rubber
Disadvantages
Use Against
Neoprene
Nitrile
Physical properties
frequently inferior to
natural rubber
Plasticizers can be
stripped; frequently
imported may be poor
quality
N/A
Aliphatics, aromatics,
chlorinated solvents,
ketones (except acetone),
esters, ethers
Fluoro elastomer
Aromatics, chlorinated
solvents, also aliphatic and
alcohols
Excellent chemical
resistance
Foot Protection
Review
Whether workers understand when protective equipment is required,
and its limitations;
Whether workers understand the most
engineering control measures provided
effective
use
of
the
PURPOSE OF LABELLING
the classification of the chemical
its hazards;
The precautions to be observed
Trade Names;
Identity of the Chemicals;
Name, address and telephone number of the
supplier; Hazard symbols;
Nature of the special risks associated with
the use of the chemical
Safety Precautions
Identification of the Batch
The statement that a chemical safety data
sheet
PETROLEUM
INDUSTRY
PETROLEUM INDUSTRY
EHS GUIDELINES
The Environmental,
Health, and Safety
(EHS) Guidelines are
technical reference
documents
with
general
and
industry-specific
examples of Good
International
APPLICABILTY
The EHS Guidelines for Petroleum Refining cover
processing operations from raw crude oil to
finished
products, including:
Refinery Fuel
Heating
Gas
Liquefied
Petroleum Gas
(LPG)
Mo-Gas
Kerosene
Diesel Oil
Oil
Fuel Oil
Bitume
n
Asphalt
Waxes
Sulfur
Petcoke
Intermediat
e Products
Oxygen-deficient
atmosphere
Fire and
explosions
PROCESS SAFETY
Process
safety
programs should be
implemented, due to
industry-specific
characteristics
complex chemical
reactions
use of hazardous
materials
multi-step reactions
OXYGEN-DEFICIENT ATMOSPHERE
The
potential
release
and
accumulation
of
nitrogen gas into
work areas may
result
in
the
creation
of
asphyxiating
venting
CHEMICAL HAZARDS
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.
Clearly identifying
hazardous HF areas, and
indicating where PPE
should be adopted
Implementing a worker
decontamination procedure
in a dedicated area
Use of scrubbing systems
to neutralizing and remove
HF prior to flaring
MAJOR HAZARDS
The most significant safety
hazards are related to the
handling and storage of
liquid
and
gaseous
substances.
The
most
significant
community
health and safety hazards
associated with petroleum
refining
facilities
occur
during the operational phase
GOOD
MANUFACTURING
PROCESS FOR
PERSONNEL
WORK CLOTHING
Fire
Resistant/Retardant
Clothing (FRC) is mandatory
for all areas of offshore
production
or
drilling
facilities. Thus, workers are
generally prohibited from
wearing clothing materials
made entirely of, or blended
with,
synthetic
materials
such as acetate, nylon,
polyester, or rayon.
FACILITIES
Production facility with hydrocarbon - containing
process equipment
Loading/ unloading or transferring hydrocarbons
where vapors are present in the atmosphere
Repairing active hydrocarbon piping, tankage or
equipment that is outside the production facility
Performing hot work activities on active hydrocarbon
equipment and piping
Performing high voltage switching operations and
maintenance
HEAD PROTECTION
Hard Hats are made from
Non-conductive plastic in
compliance with ANSIZ89. It shall be worn at all
times by personnel and
visitors when in any area
designated as requiring
head protection or where
dropped object or head
bump exposure exists.
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.
HEARING PROTECTION
Ear muffs are often
used in conjunction
with ear plugs to
protect
the
employee
from
extremely
load
noises, usually at or
above 105 decibels.
HEARING PROTECTION
Ear Plugs if placed
in the ear correctly,
will expand to fill
the ear canal and
seal against the
walls. This allows
foam ear plugs to fit
ear
canals
of
FOOT PROTECTION
Safety footwear shall be part of the basic
PPE for all personnel and shall be worn at
all times when outside accommodations,
offices, and on the following:
Offshore
Production
Construction
Drilling
Shorebases
GOOD
MANUFACTURING
PROCESS FOR
TRANSPORT SYSTEM