Engineering Standard

SAES-H-102 18 April 2019

Safety Requirements for Coating Applications
Document Responsibility: Paints and Coatings Standards Committee

Contents
1 Scope ................................................................ 2
2 Conflicts and Deviations ................................... 2
3 References........................................................ 2
4 Safety Requirements ........................................ 3
Revision Summary................................................... 9

Previous Issue: 29 October 2017 Next Planned Update: 18 April 2022

Page 1 of 11
Contact: Sangki Chi (chisx) on phone +966-13-8809571

©Saudi Aramco 2019. All rights reserved.

Document Responsibility: Paints and Coatings Standards Committee SAES-H-102
Issue Date: 18 April 2019
Next Planned Update: 18 April 2022 Safety Requirements for Coating Applications

1 Scope

This standard prescribes the minimum mandatory safety requirements applicable during
shop or field coating applications for construction, maintenance, and/or coating
maintenance programs of Saudi Aramco industrial facilities and equipment.

2 Conflicts and Deviations

Any conflicts between this document and other applicable Mandatory Saudi Aramco
Engineering Requirements (MSAERs) shall be addressed to the EK&RD Coordinator.

Any deviation from the requirements herein shall follow internal company procedure
SAEP-302.

3 References

The selection of material and equipment, and the design, construction, maintenance, and
repair of equipment and facilities covered by this standard shall comply with the latest
edition of the references listed below, unless otherwise noted.

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedure

SAEP-302 Instructions for Obtaining a Waiver of a Mandatory
Saudi Aramco Engineering Requirement

Saudi Aramco Engineering Standards

SAES-H-001 Coating Selection and Application Requirements for
Industrial Plants and Equipment
SAES-H-002 Internal and External Coatings for Steel Pipelines
and Piping
SAES-H-003 Protective Coatings for Industrial Concrete
Structures
SAES-H-004 Protective Coating Selection and Application
Requirements for Offshore Structures and
Facilities
SAES-B-067 Safety Identification and Safety Colors

Saudi Aramco General Instructions

GI-0002.100 Work Permit System
GI-0006.021 Abrasive Blasting Operations
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©Saudi Aramco 2019. All rights reserved.
Document Responsibility: Paints and Coatings Standards Committee SAES-H-102
Issue Date: 18 April 2019
Next Planned Update: 18 April 2022 Safety Requirements for Coating Applications

3.2 Industry Codes and Standards

American Society of Mechanical Engineers

ASME SEC VIII D1 Unfired Pressure Vessels

NEC Article 500 Hazardous (Classified) Locations

Occupational Safety and Health Administration (OSHA) - Construction Industry

Safety and Health Standards

29 CFR 1926 U.S. Department of Labor, Chapter XVII, Section 1926.105

The Society for Protective Coatings

SSPC-PA3 A Guide to Safety in Paint Application
SSPC-PA10 A Guide to Safety and Health Requirements for
Industrial Painting Projects

International Standard Organization

ISO 3861 Rubber Hoses for Sand and Grit Blasting -
Specification

4 Safety Requirements

4.1 Fire and Explosion Prevention

4.1.1 Smoking and/or the use of open flames shall be permitted only in
designated safe areas and never inside vessels. Welding and the use of
heating coils are prohibited in areas where coating is in progress.

4.1.2 All electrical lighting, equipment, and connections shall conform to

National Electric Code, Class I, Division 1, Group D explosion proof
requirements (NEC Article 500).

4.1.3 Solvents and paints shall not be applied to surfaces warmer than flash
point or coating manufacturer’s recommendation.

4.1.4 Work Permits for hot work, cold work, and confined space entry shall be
obtained in accordance with GI-0002.100.

4.1.5 Flammable fluids should not be used with electrostatic equipment.

Grounding of all objects, spray machines, and people.

4.1.6 Live electrical wire shall not be presented. Wet electrical equipment shall
not be operated.
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©Saudi Aramco 2019. All rights reserved.
Document Responsibility: Paints and Coatings Standards Committee SAES-H-102
Issue Date: 18 April 2019
Next Planned Update: 18 April 2022 Safety Requirements for Coating Applications

4.1.7 High pressure fluid hoses shall be grounded.

4.2 Ventilation

4.2.1 Forced ventilation shall be used in confined spaces whenever abrasive

blasting, solvent cleaning, and/or painting are in progress.

4.2.1.1 Forced ventilation shall continue until the coating is fully cured
and ready for service.

4.2.1.2 Natural ventilation (through opened manholes, etc.) shall not be

substituted for forced ventilation in confined spaces.

4.2.2 Ventilation shall ensure good air circulation with no dead air pockets in
the confined space.

4.2.2.1 The fresh air inlet shall be located near the top of the confined
space whenever practical.

4.2.2.2 The discharge opening shall be located near the bottom of the
confined space.

4.2.2.3 Supplementary fans shall be used if necessary to ensure

adequate air circulation in low spots or dead spaces.

4.2.3 Ventilation requirements for various sizes of confined spaces are given in
Table 4-1.

4.2.4 Respirable air-fed hoods shall be worn by all personnel inside confined
spaces whenever:

4.2.4.1 Blasting or spray painting is in progress.

4.2.4.2 Solvent cleaning or brush painting is in progress in a confined

space having a volume of less than 16 m³.

4.3 Health Hazards

4.3.1 Materials Safety Data Sheets for all coatings, solvents, abrasives and
cleaners in use shall be readily available on-site.

4.3.2 The appropriate personnel protection equipment listed in Table 4-2 shall
be worn. In addition, safety belts and lines shall always be used by
personnel working from unguarded platforms or in confined spaces where
a manhole accessed by a ladder is the only exit.

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©Saudi Aramco 2019. All rights reserved.
Document Responsibility: Paints and Coatings Standards Committee SAES-H-102
Issue Date: 18 April 2019
Next Planned Update: 18 April 2022 Safety Requirements for Coating Applications

4.3.3 Adequate First Aid and washing facilities shall be readily available so that
paints and solvents splashed on the body or in the eyes can be immediately
removed. Any special safety requirements listed in Materials Safety Data
Sheets of coating material shall be also available. First Aid and washing
facilities shall be checked frequently for proper functioning.

4.3.4 PPE (Personal Protection Equipment) shall always be worn and safety hats
shall be worn as required by proponent organizations.

4.3.5 Air hoses shall not be used by personnel for cleaning or cooling
themselves.

4.3.6 Solvents shall not be used by personnel for washing up.

4.4 Equipment Hazards

4.4.1 Power tools

4.4.1.1 Electrically or pneumatically driven powered mixers shall be

grounded.

4.4.1.2 Power equipment shall be operated at the speeds recommended

by the manufacturer and shall have proper safety guards.

4.4.1.3 Hearing protection shall always be worn whenever chipping

guns or pneumatic hammers are in use.

4.4.2 Abrasive Blasting

4.4.2.1 Blasting shall be equipped with a remote control shut-off

“deadman”.

4.4.2.2 The blast nozzle shall be electrically connected to an external

ground in order to prevent static electrical discharges or shocks
to operating personnel. Grounding wire shall be AWG-4 or
larger.

4.4.2.3 The blasting hose shall be the static dissipating type with external
couplings. Pressure resistance of the blast hoses shall be greater
than the maximum working pressure of blasting pots. Do not
exceed the rated pressure of the blast hose. Inspect the entire hose
before every shift. This shall be done by squeezing the entire
length of the hose at every 6 to 12 inches. Any bulges, wear or
spots identified shall be replaced.

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©Saudi Aramco 2019. All rights reserved.
Document Responsibility: Paints and Coatings Standards Committee SAES-H-102
Issue Date: 18 April 2019
Next Planned Update: 18 April 2022 Safety Requirements for Coating Applications

4.4.2.4 Respirable air-fed abrasive blasting hoods and OSHA-approved

in-line respirable air filters shall be utilized at all times by
abrasive blasting personnel.

4.4.2.5 Compressor hoses, air lines, and blast hoses shall be safety wired
at each coupling using proper safety pins.

4.4.2.6 Hearing protection shall be worn in confined spaces where

abrasive blasting is in progress. Noise levels should be less than
an average of 90 dB (OSHA PEL) per shift of 8 hours.

4.4.2.7 Before breathing air used for respiration purpose, it must be

checked to ensure it meets the quality requirements. They shall
be re-tested every quarter to ensure that air quality remains
satisfactory.

4.4.2.8 Cleanliness of air supplied to Blasters Helmet shall be as per

OSHA Grade D.

4.4.2.9 Compressor for breathing air should not be kept in area where
dust, fumes, or solvent vapors are present.

4.4.2.10 Breathing air should be free from moisture and oil.

4.4.2.11 Carbon Monoxide Alarm should be fitted in the breathing

airline and the same tested before every shift.

4.4.2.12 Do not mix up parts of different manufacturers in breathing

airline.

4.4.2.13 All components in the breathing airline should be checked daily.

4.4.2.14 NIOSH approved air respirator should be used in the blasters

helmet.

4.4.2.15 Vessels such as air receivers that are used as a surge tank between
the compressor and the blasting pot shall be manufactured and
stamped in accordance with ASME SEC VIII D1, Unfired Pressure
Vessels. They shall be hydrotested at a pressure as recommended
by the vessel manufacturer at ambient temperature using clean
water. These vessels shall be revalidated by hydrotesting at least
annually and the test certificates shall be submitted to the Saudi
Aramco Inspector for verification.

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©Saudi Aramco 2019. All rights reserved.
Document Responsibility: Paints and Coatings Standards Committee SAES-H-102
Issue Date: 18 April 2019
Next Planned Update: 18 April 2022 Safety Requirements for Coating Applications

4.4.2.16 All pressure relief valves, gauges, and devices shall be tested
annually and tagged with the expiration date. The test certificates
shall be submitted to the Saudi Aramco Inspector for verification.

4.4.2.17 All blasting and coating equipment and associated attachments

shall be adequately earthed to avoid electrostatic discharges.

4.4.3 Solvent Cleaning

4.4.3.1 Benzene, gasoline, carbon tetrachloride, and chlorinated

hydrocarbons with low threshold limit values (less than
20 ppm) shall not be used.

4.4.3.2 Suitable gloves shall be worn while solvent cleaning along

with other applicable personnel protection equipment.

4.4.3.3 Suitable Respirator shall be worn during solvent cleaning.

Solvent cleaning shall be done in well ventilated areas.

4.4.4 Coating Preparation and Equipment Cleaning

4.4.4.1 Coatings shall be prepared and mixed in an adequately

ventilated and shaded area away from sunlight or any other
source of ignition. Use eye protection (goggles), respirator or
mask and compatible protective gloves.

4.4.4.2 Electrically or pneumatically driven power mixers shall be

grounded.

4.4.4.3 Avoid splash or spillage during mixing. Clean spilled paints

immediately using proper cleaning solvent.

4.4.4.4 Safety instructions or MSDS (Material Safety Data Sheet) of

coating material which are provided from coating manufacturer
shall be followed.

4.4.5 Airless Spray Paint Application

4.4.5.1 Airless spray guns shall never be pointed at anyone or at any

part of the body.

4.4.5.2 The tip guard shall always be in place on the airless gun while
spraying.

4.4.5.3 Leather gloves shall be worn by the operator whenever the

airless spray gun is in use.
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©Saudi Aramco 2019. All rights reserved.
Document Responsibility: Paints and Coatings Standards Committee SAES-H-102
Issue Date: 18 April 2019
Next Planned Update: 18 April 2022 Safety Requirements for Coating Applications

4.4.5.4 The trigger safety latch shall be engaged whenever the airless
gun is left unattended.

4.4.5.5 Hoses, pumps, and accessories shall never be operated at

pressures exceeding their rated pressure. In no case shall the
working pressure in the paint line exceed 34.5 MPa (5,000 psi).
Safety pressure relief valves shall be used on outbound side of
the pressure pump(s).

4.4.5.6 The pump shall be shut down and the fluid pressure in the
system relieved before servicing or cleaning any components,
including clogged spray tips.

4.4.5.7 Hoses shall be grounded, anti-static type.

4.4.5.8 Airless spray equipment shall not be operated unless all

grounds (earths) are in place, connected, and in good condition.
Grounding wire shall be AWG-4 or larger.

4.4.5.9 Airless spray equipment shall not be operated if any of the

pressure system components is not in good condition.

4.4.5.10 Solvents shall not be flushed into containers that are hotter than
50°C.

4.4.5.11 Emergency medical care shall be obtained immediately if any

high pressure fluid from the airless equipment penetrates the
skin. (High pressure fluid injection injuries can be extremely
serious, including the need for amputation).

4.4.5.12 Do not use your hands or body to stop any leak in the airless
spray lines.

4.4.5.13 Never exceed the working pressures of Airless Spray system.

4.4.5.14 Spray tip shall be aligned properly to avoid back spray

4.4.5.15 Never inter change fluid and air hoses during application.
Color code for air hose shall be Red and fluid hose shall be
Black. Spray hoses shall be made of solvent resistant material.

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©Saudi Aramco 2019. All rights reserved.
Document Responsibility: Paints and Coatings Standards Committee SAES-H-102
Issue Date: 18 April 2019
Next Planned Update: 18 April 2022 Safety Requirements for Coating Applications

Revision Summary
24 October 2012 Revised the “Next Planned Update”. Reaffirmed the contents of the document, and reissued
with editorial revision to remove the committee members list and change the primary contact
person.
29 October 2017 Major revision to referenced international standards; added new safety requirements for
electrical equipment, high pressure hoses, air receivers, blasting equipment, air quality, and
noise level; and required safety certifications were addressed.
18 April 2019 Minor revision to revise and clarify some requirements related to air receiver and blasting
hoses.

Summary of Change Form

Paragraph Change Type
No. Technical Change
No. (New, Modification…)
1 4.4.2.3 Modification Revise the requirement for blasting hose.

2 4.4.2.15 Modification Revise the requirement for air receiver.

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Document Responsibility: Paints and Coatings Standards Committee SAES-H-102
Issue Date: 18 April 2019
Next Planned Update: 18 April 2022 Safety Requirements for Coating Applications

Table 4-1 - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

m³ BBL L/s cfm

16 100 472 1,000

80 500 1,180 2,500
160 1,000 2,360 5,000
800 5,000 4,720 10,000
1,600 10,000 7,080 15,000
4,000 25,000 9,440 20,000

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Document Responsibility: Paints and Coatings Standards Committee SAES-H-102
Issue Date: 18 April 2019
Next Planned Update: 18 April 2022 Safety Requirements for Coating Applications

Table 4-2 - Personal Protective Equipment to be Worn

or Used during Surface Preparation and Paint Application

Key: O = Outdoors
C = Confined Spaces
OSHA-Approved
Respirable Respirator; Face
Airfed Hood Chemical Dust Shield
Type of Work to and Filter Cartridge Respirator (1)
be Performed 21-444-934 21-370-800 21-370-500 21-426-121
21-443-500 21-370-810 21-426-125
21-370-820 21-426-142

O C O C O C O C

Surface Preparation

Wire Brushing, X X X X
Chipping, Scrapping
and Grinding

Abrasive Blasting
- operator X X
- other workmen X X X X X

Paint Removing X X X

Solvent Cleaning X X X
------------------------------------------------------------------------------------------------------------------------------------------------------
Brush Spray Brush Spray Brush Spray Brush Spray
Paint Application O C O C O C O C O C O C O C O C
------------------------------------------------------------------------------------------------------------------------------------------------------

Epoxy and Coal\ X X X X X

Tar Epoxy

Alkyd X X

Inorganic Zinc X X

Chlorinated Rubber X X

Bituminous X X
-----------------------------------------------------------------------------------------------------------------------------------------------------

Note: (1) Face shields shall always be used when working overhead.

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Document Responsibility: Paints and Coatings Standards Committee SAES-H-102
Issue Date: 18 April 2019
Next Planned Update: 18 April 2022 Safety Requirements for Coating Applications

Table 4-2 - Personal Protective Equipment to be Worn

or Used during Surface Preparation and Paint Application (Cont'd)

Key: O = Outdoors
C = Confined Spaces

Goggles Gloves; Gloves; Hearing

Type of Work to Safety Impact Leather Rubber Protection
be Performed 21-434-249 21-432-353 21-432-630 21-327-100/105/110/272
O C O C O C

Surface Preparation

Wire Brushing, X X X X
Chipping, Scrapping
& Grinding

Abrasive Blasting
- operator X X X X
- other workmen X X X
- in vicinity

Paint Removing X

Solvent Cleaning X
---------------------------------------------------------------------------------------------------------------------------------------------------
Brush Spray
Paint Application O C O C ALL
---------------------------------------------------------------------------------------------------------------------------------------------------

Epoxy and Coal\ X

Tar Epoxy

Alkyd X X X

Inorganic Zinc X X X

Chlorinated Rubber X X X

Bituminous X X X

Polyurethane X X X

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