Northwest Regional Maintenance Center
PSNS&IMF
Industrial Management Department
Building 844
808 Burwell St.
Bremerton, WA 98314
COVER SHEET FOR PROCESS CONTROL PROCEDURE (PCP)
======
Section 1: To be completed by the contractor.
Northwest RMC Control Number: Revision: -
(ex. ABC-MM0001-CY)
Prime Contractor Reviewed and Approved by: ______
Prime Contractor POC Name: POC Phone Number:
Contract Number: Work Item Number: Mod: W/I Para:
Ship Name & Hull Number: USS Project/Avail:
Description: CHT PIPING SYSTEM MAINTENANCE
Category: CHT COFFERDAM FLUSH WELDING OTHER:
Standard Template Submitted: Yes No Change(s) Made to Standard: Yes No
Approved OEM/Government Procedure: Yes No Title & Doc #: ______
Date Submitted to NWRMC: Date Developed: Date Work Scheduled to Begin:
Document or Reason for Late Authorization of Work Date of Late Authorization:
(If submitted less than 14 days of scheduled work)
Sub Contractor Reviewed and Approved by: ______
Sub Contractor Co. Name: POC Name:
Sub Contractor Reviewed and Approved by: ______
Sub Contractor Co. Name: POC Name:
Remarks:
======
Section 2: To be completed by the NWRMC reviewer.
Technical Review Completed By: ______Code: ______Approval Date: ______
For ESR: ______NWRMC #: ______
Safety/Environmental Division Reviewed (as applicable): ______
Remarks:
CHT PIPING SYSTEM MAINTENANCE
Section 2 – Personnel Qualifications
2.1 All personnel involved with the maintenance or repair of the CHT piping system or components are experienced journeymen. They will be under the direct supervision of a lead man or foreman with previous CHT system maintenance experience.
2.2 Marine Chemists shall be certified in accordance with the National Fire Protection Association (NFPA). Competent designated personnel shall be certified in accordance with (OSHA) 29CFR, (Part 1915.7).
2.3 A briefing will be conducted prior to beginning work to ensure personnel have direct knowledge of the requirements of this procedure and the safety requirements of the job. Accomplishment of the briefing will be documented on attachment 6.2.
Section 3 – Process Description
3.1 PROCEDURE CONTROLS
3.1.1 The methods used to ensure proper performance of maintenance will be in compliance with this Process Control Procedure, the basic Work Item Specification, and applicable references, in addition to on-site Marine Chemist requirements, on-sit Supervision and Quality Assurance Inspections.
3.1.2 The safety brief shall include a handover-hand inspection and verification of the tagged-out piping/mechanical/electrical system Ensure/verify with Ship’s Force that all points of necessary system isolation have been properly tagged out. Attachment 6.1 is a diagram of affected piping to be isolated and tagged out and affected spaces that will be directly impacted. A copy of the WAF, ship’s EOSS depicting the tag-out, along with a copy of the Tag-Out Record Sheet (TORS) will also be posted at the job site.
3.1.3 Establish cleaning stations at the work areas and provide portable cleaning stations for personnel or individual component removal as necessary. Assemble and stage spill kits in case of effluent leakage in the work area. This will include absorbent material, absorbent pads, chlorine bleach, hand sanitizer and disinfectant soap.
3.1.4 Ensure adequate temporary ventilation is in place at the work site. Temporary non-sparking ventilation shall be installed and operating prior to the Marine Chemist’s arrival. The ventilation shall be maintained in accordance with the Marine Chemists requirements. (Discharging to a safe location external of the ship)
3.1.5 Containment fixtures will be placed underneath components being opened or removed. Minimal residual fluids are expected to be present in the piping and will drain into the containment. Residual fluids that do drain out into the containment will be removed and disposed of in accordance with Reference 5.6. (PSNS) or 5.7 (Everett) depending on the location of work.
3.1.6 Flush and /or vent the affected CHT piping with water and chlorine bleach prior to opening the system. Ensure the Certified Marine Chemist is standing by to certify the space and piping are gas free, or make recommendations.
3.1.7 Upon system opening and after gas free certification is received, blank, cap or bag all openings to prevent spillage from all open components and piping.
3.1.8 Accomplish the scope of maintenance or repair as stated in the work specification. Upon installation aboard ship, an operational test will be conducted IAW the work item.
3.1.9 Once the work has been accomplished, all blanks, caps or bags may be removed and the final connection made up. Per the Marine Chemist instructions, either the Marine Chemist or a Shipyard Competent Person shall be present upon blank/spool piece removal to monitor for safe conditions or Per the Marine Chemist instructions,
3.1.10 A copy of this procedure shall be on the job site during the performance of work.
3.2 GOVERNMENT NOTIFICATION
3.2.1 (V) (G) START OF PROCEDURE:
Provide Government notification for start of procedure prior to commencement. This will also include any necessary joint Ship’s Force/Code 400/Contractor safety briefing.
3.2.2 (V) (G) Operational Test
Provide Government notification once system is restored, to demonstrate satisfactory operational and unobstructed flow.
3.3 INSPECTION AND DOCUMENTATION FORMS
3.3.1 Start of procedure will be documented on a Test/Inspection Event Authorization form and enclosure 6.2 PCP Direct Knowledge attendances Form.
3.3.2 Marine Chemist Certificate
3.3.3 Shipyard Competent Person Log of Tests and Inspections
3.4 ACCEPTANCE AND REJECTION CRITERIA
3.4.1 Certification of Gas Free status by An NFPA Certified Marine Chemist. (Certify Enter with Restrictions, Safe for Worker/or Safe for Hot Work).
3.4.2 Satisfactory operational test, allowable leakage and unobstructed flow; None.
Section 4 - Hazardous Materials / Handling Requirements:
4.1 SAFETY REQUIREMENTS
4.1.1 Barrier tape shall be placed surrounding the work area as needed with signs that read:
WARNING – CHT Piping System Work
Authorized Personnel Only
No Eating, Drinking, or Smoking.
4.1.2 Plastic sheeting will be used as needed to protect equipment from effluent in case of spill.
4.1.3 Temporary non-sparking ventilation shall be installed and operating prior to the Marine Chemist’s arrival. The ventilation shall be maintained in accordance with the Marine Chemists requirements.
4.1.4 An NFPA Certified Marine Chemist will be present to certify the space and the piping gas free at the initial opening/breaking of all CHT piping to monitor for unsafe conditions. No work shall be accomplished until the space and piping are certified gas free by the Marine Chemist. The ventilation shall be maintained in accordance with the Marine Chemists requirements, when any temporary blanks or spool pieces are removed to facilitate continuing work , either the Marine Chemist or a Shipyard Competent Person shall be present to monitor for safe atmosphere and conditions or In accordance or with the Marine Chemists requirements. Atmospheric conditions shall be monitored and maintained “safe for workers” in accordance with the Marine Chemists requirements
4.1.5 Safety department shall ensure all personnel required to wear breathing apparatus IAW (Ref 5.1) 593-4.3.1.2 are medically qualified and trained.
4.1.6 Personnel shall wear protective clothing including overalls, rubber boots, rubber gloves, eye/face shield (NSTM 593-4.3.3 c) and hair covering as appropriate when contact with CHT water is possible. Protective clothing shall not be used for more than one shift.
4.1.7 All protective clothing shall be assumed to be contaminated, and handled accordingly. Protective clothing shall be placed in plastic bags at the conclusion of work at the worksite. Fabric clothing shall be placed in one bag for normal laundering. Rubber boots and gloves shall be placed in separate bags prior to being sent out for washing in hot water and a stock detergent prior to reuse by personnel. All bags must be sealed and marked to indicate the nature of its contents before removal from the worksite.
4.1.8 All components that are to be removed from the CHT system are to be placed in heavy plastic bags to prevent the spread of contamination.
4.1.9 All piping that is removed from the CHT System shall be sealed at all open ends in accordance with Ref 5.4.
4.1.10 In the event an employee is exposed to Black Water as a result of system cross contamination, and only by direction of a Licensed Health Care Practitioner, a 3-injection series immunization program may be offered to the exposed employee. (This does not apply to nor is it intended as a substitute for the required PPE during work being conducted on shipboard systems, pipes, valves and tanks related to CHT). This immunization series is only in the event of actual personnel exposure.
Because the Hepatitis B virus (HBV) is so aggressive, if you decline this prophylactic treatment, you will be required to sign a waiver to that effect.
4.1.11 In case of emergency or spill, notify Prime contractor Safety Dept. and the Ship’s Quarter deck immediately. Suspend all operations. List of emergency phone numbers is provided in on attachment 6.6 and shall be used as appropriate for the spill, causality or other emergency.
4.1.11.1 If the spill is deemed to be Black Water or sewage from system cross contamination, clean up the media using soap and water and a 10% solution of chlorine bleach to disinfect. All “organic material: raw sewage solids found where free liquids are still present – add kitty litter to absorb the liquid. Double bag the media (this is done to discourage vectors and cut down on the smell). Mark the bags with “Raw Sewage Solids” to identify the contents.
At no time may any person contaminated with any sewage leave the immediate area until decontaminated. If personnel are contaminated with sewage, decontaminate with mild soap and water solution or Beta-dine as provided by Safety.
Contaminated protective clothing shall be placed in plastic bags at the conclusion of work at the worksite. Fabric clothing shall be placed in one bag for normal laundering. Clothing must not be used for another shift and must be laundered in hot water and detergent. Rain gear must be rinsed and disinfected. Rubber boots and gloves shall be placed in separate bags prior to reuse by personnel. All bags shall be sealed and marked to indicate the nature of its contents before removal from the work site.
All waste generated during the cleaning operation and process will be disposed in accordance with local, state, and federal regulations.
Disposal shall be in accordance with: Environmental, Safety, and Health Requirements for the Bremerton Naval Complex, Contractor will be using bleach, Beta-dine, and detergent as disinfectant only. Waste will be handled in accordance with pre designated WIS. (Contractor expects no Hazardous Waste)
In the event spaces become contaminated with sewage as a result of leaks, spills, or sewage system backflow, the space shall be evacuated immediately. The spill area shall be secured from traffic, and a Certified Marine Chemist shall test the area to ensure that the atmosphere is within acceptable gas limits. A safety watch with respiratory protection (Supplied Air Respirator/Self-Contained Breathing Apparatus [SAR/SCBA] or air-line mask) shall be posted at the compartment access during cleanup. The spilled sewage shall then be removed or washed down. Respiratory protection shall be used if the atmosphere is not within acceptable limits. If the atmosphere is within acceptable limits, cleanup may be accomplished without respiratory protection; however, respiratory protection shall be kept on hand during the cleanup. The area shall be recertified as gas free at least every two (2) hours and every hour for ambient temperatures above 32.2° C (90° F), or more frequently if deemed necessary by the Marine Chemist. The need for temporary ventilation shall be determined by the Marine Chemist. A final wash down shall be accomplished with hot, potable water and stock detergent. In addition, food service spaces, berthing areas, and medical spaces shall be treated with an approved disinfectant such as NSN 6840-00-7534797, Disinfectant, Germicidal Fungicidal Concentrate (Phenol Type); or NSN 6840-00-526-1129, Disinfectant, Germicidal and Fungicidal Concentrate (Iodine Type). To be effective, these agents shall be used according to the instructions printed on the labels.
4.1.11.2 If the spill is deemed to be CHT Water, clean up the media using soap and water.
a. All waste generated during the cleaning operation and process will be disposed in accordance with Environmental, Safety, and Health Requirements for the Bremerton Naval Complex.
4.2 HAZARDOUS MATERIALS
4.2.1 All waste generated during the cleaning operation and process will be disposed in accordance with local, state and federal regulations
4.2.2 The methodology used to limit the quantity of chlorine bleach used to disinfect the CHT system shall be determined by the marine Chemist.
4.2.3 Chlorine bleach should be considered as hazardous material and handled accordingly.
Section 5 – REFERENCES: (Local, Regional, and/or State Requirements)
5.1 S9086-T8-STM-010/Chapter-593, POLLUTION CONTROL
5.2 NAVSEA STANDARD ITEM 009-88
5.3 NAVSEA STANDARD ITEM 009-09
5.4 NAVSEA STANDARD ITEM 009-24
5.5 NFPA Standard 306 Standards for the control Gas Hazards on Vessel
5.6 5090 Ser. 106/0077 Dated May 10, 2013
5.7 Environmental Guide for Contractors, EVE. SOP – Contractor Guide OCT 2015
Section 6- ATTACHMENTS
6.1 Effected System Drawing.
6.2 PCP Direct Knowledge Attendance Form
6.3 Competent Person Log
6.4 MSDS Bleach
6.5 MSDS Hand Sanitizer
6.6 MSDS Surgical Scrub
6.7 Emergency Contact List
6.8 Warning Sign
History of Change
Page 2