OPITO Blaster-Sprayer (Level 2)

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1 OPITO Blaster-Sprayer (Level 2) Standard Title Code OPITO Blaster-Sprayer Competence Standard (Level 2) 9125

2 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. Revision 2 October 2016 Page 2 of 46

3 AMENDMENTS Amendment & Date Pages Changes made by Revision 0 (March 2008) Checked by Approved by 1 Updated text to reflect revised content after Trainee Blaster-Sprayer Training Pilot Course 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 7 T. Wilson J. Cameron J. Cameron 19-Dec 2008 Rev.1 Converted from an OPITO non-certified standard to an OPITO-certified standard at Industry s request and full review completed. All M. Carr Industry Work Group P. Lammiman Revision 1 (Dec 2011) 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 Revision 2 October 2016 Page 3 of 46

4 Rev.2 Complete Review of Standard within 2015 Work Group incorporating 2016 rebranding of Standards All M. Foo SA EH Any amendments made to this standard by OPITO will be recorded above. Revision 2 October 2016 Page 4 of 46

5 Contents Introduction...6 SECTION A The Blaster-Sprayer Competence Assessment Level A.1 Target Group for the Blaster-Sprayer Competence Assessment Level A.2 Candidate pre-requisites for the Blaster-Sprayer Competence Assessment Level A.3 Physical and stressful demands of the Competence Assessment... 9 A.4 Aim and objectives of the Blaster-Sprayer Competence Assessment A.5 Competence Assessment Outcomes A.6 Candidate Competence Assessment process A.7 Duration and timing of the Competence Assessment Level A.8 The Blaster-Sprayer Competence Units Level SECTION B Centre Resources B.1 Location of Assessment B.2 Staff B.3 Facilities B.4 Equipment (Materials) SECTION C Administration and Certification C.1 Joining Instructions C.2 Validity and Renewal C.3 Certification & Recording C.4 Administration Glossary of terms and abbreviations Appendix 1: Level 1 (WE) Logbook Workplace Experience Requirements Appendix 2: Practical Assessment Process Appendix 3: OPITO Level 2 Competence Assessment Record Revision 2 October 2016 Page 5 of 46

6 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-Sprayer Training Standard (Level 1) and also the Blaster-Sprayer Competence Assessment Standard (Level 2). 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. This standard includes on-the-job workplace experience tasks for personnel before undertaking the Level 2 competence assessment. The blaster/sprayer s route to achieve OPITO training and competence certification is comprised of the following stages: The Blaster/Sprayer Training and Competence Levels Level 1 The Initial Training Programme: Delegates successfully completing the Initial Training Programme will be awarded an OPITO Level 1 certificate; this entitles the delegate to progress to Level 1 (WE): Workplace experience tasks Level 1 (WE) Workplace Experience Tasks: Level 1 (WE) specifies the series of workplace experience tasks which the candidate will be required to complete in order to gain relevant experience in the workplace. Each task must be logged in a log book provided by the Training Provider. Level 2 Competence Assessment: Level 2 specifies the assessment process and criteria for the candidate to demonstrate competence in the role of a Blaster/Sprayer. Successful candidates will be awarded an OPITO certificate of competence. Note: An experienced Blaster/Sprayer can opt to take Level 2 assessment without completing Level 1, providing they have verifiable evidence of blasting/spraying experience. The flow chart on the next page illustrates the routes required to achieve OPITO training and competence certification. Revision 2 October 2016 Page 6 of 46

7 Employee has evidence of appropriate experience as a Blaster Sprayer Employee nominated by company for further development Person selfsponsors to become a Blaster Sprayer Self-sponsored Blaster Sprayer with experience but no verifiable evidence of workplace experience Employee deemed ready for assessment by employer Further training Delegate undertakes and experience Blaster Sprayer Training required course at OPITOapproved Undergoes a pre- training site assessment training course. (See OPITO Blaster Training provider will decide Sprayer Training whether candidate is Standard) deemed ready for assessment No Delegate successfully completes training No Delegate cannot progress to the next stage without successfully completing the OPITO training programme. Yes Yes Delegate awarded OPITO approved certificate and deemed a Level 1 Blaster Sprayer Employer sponsored Level 1 Blaster Sprayer transfers to worksite for workplace experience - recorded in log book Further training required No Candidate deemed ready for assessment Level 1 Blaster Sprayer completes log book and deemed ready for Level 2 assessment Yes Key: Starting point for training and competence route Level 1 Candidate assessed against OPITO Blaster Sprayer Competence Standard Candidate successful No 'Candidate' completes appropriate remedial programme. Decision Candidate becomes an OPITO- certified Blaster Sprayer (Level 2) to OPITO Competence Standard Revision 2 October 2016 Page 7 of 46

8 SECTION A The Blaster-Sprayer Competence Assessment Level 2 A.1 Target Group for the Blaster-Sprayer Competence Assessment Level 2 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 Level 2 Candidates for Competence Assessment Level 2 require: a) A valid OPITO-approved Blaster/Sprayer Training Level 1 Certificate AND b) A fully completed and valid logbook, based on the OPITO Blaster/Sprayer Training Level 1 (WE) Workplace Experience requirements OR c) A *formal letter from the candidate s current or previous employer stating that the candidate has been employed as a Blaster-Sprayer within the last two years, AND **documented evidence of having been employed as a Blaster-Sprayer over the last two years. The formal letter and documented evidence must be authenticated by the assessment centre prior to confirming the booking. *The formal letter must include details of the employer or employer representative s position in the company, full contact details, and be signed and dated by the employer or employer representative **documented evidence - As a minimum requirement: the candidate s CV. Revision 2 October 2016 Page 8 of 46

9 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. The training establishments should also ensure that delegates have an appropriate medical screening relevant to the discipline being undertaken. For example, questions about breathing problems and allergies should be asked before a delegate can come into contact with blasting/spraying materials. 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. 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. Revision 2 October 2016 Page 9 of 46

10 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 of Level 2 are specified in the Performance and Underpinning Knowledge and Understanding criteria of the Competence Unit in Section A.8 and the successful completion of the written Knowledge Assessment test. Revision 2 October 2016 Page 10 of 46

11 A.6 Candidate Competence Assessment process The candidate Blaster-Sprayer must be assessed by a suitably qualified assessor; refer to Section B.1 for the Level 2 Assessor requirements. Level 2 Assessment is comprised of two parts: 1. Knowledge Assessment 2. Practical assessment The candidate will be assessed against the performance and underpinning knowledge and understanding criteria specified in the Units within Section A.8 of this standard. Knowledge Assessment Candidates will be required to take a written theory test which covers the underpinning knowledge and understanding criteria specified in A.8. The written test pass mark is 80%. All questions must be clearly referenced against the underpinning knowledge and understanding criteria and there must be a minimum of two questions per Unit Criteria. 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-approved Centre must ensure that more than one question paper is produced from the bank of questions within this document. The question papers must be changed frequently. The written test can be taken by the candidate either before or after the practical assessment. The practical assessment requires the assessor to observe the candidate perform the specified tasks to the required standard. The Practical Assessment process is specified in Appendix 3. The Blaster-Sprayer Competence Assessment Level 2 certificate will only be awarded if the candidate successfully completes both the Knowledge Assessment and the Practical Assessment. The successful candidate i.e. the candidate that fully meets the knowledge and practical assessment standard will then be deemed certified to undertake blasting/spraying operations in the workplace. Candidate does not meet the Standard Where a candidate does not meet the required assessment outcomes: 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 with a written report identifying why the candidate was unsuccessful and suggest any further training requirement within 7 days of the assessment. If the candidate does not meet the requirements of the Level 2 Standard: No certificate will be awarded and the candidate must retake the OPITO Blaster-Sprayer Competence Assessment. Revision 2 October 2016 Page 11 of 46

12 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 Level 2 The expected duration for the assessment is: 8 hours for a group of 6 candidates (which includes 1 hour allowed for the written test). A.8 The Blaster-Sprayer Competence Units Level 2 This section specifies the Level 2 Unit s assessment criteria. The units comprise both the Performance Criteria and the Underpinning Knowledge and Understanding Criteria. 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 Revision 2 October 2016 Page 12 of 46

13 Competence Assessment Units 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 Element 1.1 Performance Criteria The candidate must demonstrate the following: An understanding of the main elements of typical: permits, client safe systems of work, company procedures and risk assessments Interpreting MTDSs, client specifications and to decide on the appropriate blasting or coating method Conduct work according to a work pack with associated procedures and risk assessments How to contribute to a Tool Box Talk (TBT) Ability to work within a team Correct storage of equipment after use. Element 1.1 Underpinning knowledge and Understanding Criteria The candidate must know and understand the following: How to obtain relevant operational policies, procedures, instructions, codes of practice and standards Typical workplace reporting procedures relevant to the Blaster-Sprayer How to get specific information required for project records 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. Revision 2 October 2016 Page 13 of 46

14 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 Element 2.1 Performance Criteria The candidate must demonstrate the following: Ensure that personal protective equipment (PPE) is available for use, in good repair and appropriately used Ensure tools/equipment are within specification and certification dates Record exposure time for HAVS records 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 Keep the work area as clean and tidy as possible Identify and report unsafe equipment Work safely in accordance with operational requirements and associated safe systems of work. Revision 2 October 2016 Page 14 of 46

15 Element 2.1 Underpinning knowledge and Understanding Criteria The candidate must know and understand the following: Typical sources of safety information and safety observation systems of a site/ installation How to interpret a basic task-based risk assessment The use and care of various types of PPE & RPE related to Blaster-Sprayer operations Awareness of RPE tests and how often they should be done Typical hazards for blasting/painting activities The consequences of faulty or disconnected dead man units How and when to connect anti-static earth lines Typical precautions to take for working on live lines* Relevant elements of COSHH Assessment and how to interpret key points of a MSDS Appropriate communications methods when working as part of a team Typical problems associated with HAVS and the importance of recording exposure times Use of safe access equipment and platforms, and the Scafftag system Typical manual handling hazards and how mechanical lifting and handling aids can be used to overcome these Typical hazards associated with Blaster-Sprayer operations in confined spaces Typical methods for controlling Blaster-Sprayer-related risks in confined spaces Maintaining an emergency escape route from the work area 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. Revision 2 October 2016 Page 15 of 46

16 Element 2.2 Protect third party personnel, adjacent surfaces and the environment Element 2.2 Performance Criteria The candidate must demonstrate the following: Protect* adjacent surfaces, plant and equipment not being blast-cleaned or coated Protect prepared or painted work surfaces Limit access to the area with appropriate signs and barriers Ensure waste is limited by correctly following instructions for mixing ratios. Element 2.2 Underpinning knowledge and Understanding Criteria The candidate must know and understand the following: How to develop a spill plan, locate and position spill containers How to limit dust, debris and hazardous material from contaminating the environment and harming personnel How to contain spray painting or blasting during windy conditions 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. Revision 2 October 2016 Page 16 of 46

17 UNIT 3 Element 3.1 Operate compressor equipment Operate compressor equipment Element 3.1 Performance Criteria The candidate must demonstrate the following: Completing compressor familiarisation, pre-start checks and correctly connecting relevant equipment for the work Checking area in proximity of compressor air intake is clear Checking for foreign objects in the compressor case Correctly start up the compressor following relevant instructions or procedures Monitor compressor to ensure it is functioning properly during abrasive blasting or spray painting Shutting down compressor correctly and completing post-stop checks. Element 3.1 Underpinning knowledge and Understanding Criteria The candidate must know and understand the following: Awareness of the different types of compressors applicable to Blaster-Sprayer operations and their applications Typical protection devices fitted to compressors How to shut down the compressor in an emergency The purpose and use of pre-start up checks Typical hazards and precautions associated with multiple users sharing the same compressor 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. Revision 2 October 2016 Page 17 of 46

18 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 Element 4.1 Performance Criteria The candidate must demonstrate the following: Identify and correctly don appropriate PPE for mechanical preparation tasks Degrease and clean surfaces in accordance with work pack* guidelines and procedures Correct use of mechanical power tools for surface preparation. *Work pack: Assessment Centre to provide work pack for assessment. Element 4.1 Underpinning knowledge and Understanding Criteria The candidate must know and understand the following: Reasons for correctly preparing a surface The types of surfaces commonly treated by industrial Blaster-Sprayers The purpose of surface pre-cleaning the surface prior to conducting surface preparation 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. Revision 2 October 2016 Page 18 of 46

19 Element 4.2 Prepare surfaces using abrasive blasting Element 4.2 Performance Criteria The candidate must demonstrate the following: Identify appropriate PPE for specific Blaster-Sprayer tasks Correctly don PPE and ensure respiratory equipment is functional Install tear-offs on the blast hood Check equipment is in safe working order Load, monitor and maintain the supply of abrasive during the project Assemble blasting equipment correctly Monitor the air supply for any malfunction Use the appropriate technique to blast identified surfaces Ensure the visual surface preparation and blast profile are checked at agreed hold points Contain spent materials in a safe and secure manner Ensure that cleaned surfaces are to the required standard Shutdown and make safe the blasting equipment Transfer used waste materials to the appropriate disposal site Reinstate the worksite in accordance with operation s requirements. Element 4.2 Underpinning knowledge and Understanding Criteria The candidate must know and understand the following: Scope: 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 Factors affecting air quality supplied to blasting equipment and breathing air supplied to hoods The differences between dry grit blasting and wet slurry blasting Typical pressure-relief systems and components associated with blasting equipment Typical quality control checks on surfaces that have been abrasive blasted The consequences and control of flash rusting in the case of wet slurry blasting. Blasting equipment; to include equipment for dry grit blasting or wet slurry blasting. Revision 2 October 2016 Page 19 of 46

20 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 Element 5.1 Performance Criteria The candidate must demonstrate the following: Conduct visual checks of work surfaces for contamination and defects; to include checks for runs, sags, grit inclusion and overspray Prepare coatings to client specification by following the manufacturer s instructions Select and correct spray tip size needed for spraying different materials and surfaces Allow for the correct time between further coatings. Element 5.1 Underpinning knowledge and Understanding Criteria The candidate must know and understand the following: Typical types of coatings, to include: batch numbers and shelf life of the coatings Actions to take if experiencing unacceptable variations in environmental conditions The effects of working outside acceptable variations in environmental conditions Time allowance between coats Symptoms causes and corrections of common coating failures. Revision 2 October 2016 Page 20 of 46

21 Element 5.2 Apply coatings with brush (and roller when appropriate) Element 5.2 Performance Criteria The candidate must demonstrate the following: Identify and don appropriate PPE for specific hand painting application tasks Use the appropriate technique to stripe coat surfaces using a brush Use the appropriate technique to apply the coating using a brush and/or roller Ensure that coated surfaces are acceptable to the supervisor/inspector Check wet film thickness using a wet film gauge How to clean and store paint brushes and rollers. Element 5.2 Underpinning knowledge and Understanding Criteria The candidate must know and understand the following: Types of paint brushes/rollers and selecting the correct type for the application The reasons for stripe coating effectively The purpose of conducting wet film thickness checks during application How to clean and store paint brushes and rollers. Scope: Surfaces; to include: broad areas, angled areas, linear items and complex shapes. Revision 2 October 2016 Page 21 of 46

22 Element 5.3 Apply coatings with spray paint Element 5.3 Performance Criteria The candidate must demonstrate the following: Don appropriate PPE and ensure respiratory equipment is functional Select the appropriate paint spraying equipment (including correct spray tip), for the task and ensure that it conforms to specific job requirements Identify the coatings suitable for the task Correctly assemble paint spraying equipment Correctly mix the paint Conduct checks on paint spraying equipment, compressed air equipment and pressurised lines to ensure they are in safe working order Monitor the hood and spray equipment air supplies and take appropriate action on any malfunction Load, monitor and maintain the supply of paint during operations Use the appropriate technique to spray surfaces to meet specifications Check wet film thickness using a wet film gauge Ensure that coated surfaces are acceptable to the supervisor/inspector Correct method of cleaning, shutting down and making safe the paint spraying equipment. Element 5.3 Underpinning knowledge and Understanding The candidate must know and understand the following: The main differences between hood lines and paint spray lines Methods for applying non-slip coatings How to check wet film thickness during application The purpose of surface cleanliness checks and how to perform them How to report defects and faults in equipment The consequences of not flushing out paint spray lines properly Awareness of other types of spraying equipment 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. Revision 2 October 2016 Page 22 of 46

23 SECTION B Centre Resources B.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. onlocation. (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 B.2). (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 Revision 2 October 2016 Page 23 of 46

24 B.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 Competence Assessment Level 2. Assessor Requirements Assessors must: (a) (b) (c) (d) (e) (f) (g) 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 Level 2 certificate, or II. An equivalent relevant qualification or certification (e.g. a NACE-level 3 certificate). Hold an industry-recognised assessor s qualification e.g. A1, D33, L20, the OPITOapproved Competence Assessor Certificate, or equivalent qualification. Fully understand the OPITO-approved Assessment Centre s internal quality assurance of assessment processes and practices. Fully understand the requirements of this Industry Standard. Fully understand the OPITO requirements for recording assessment decisions and securely maintaining accurate records of these. Participate in regular standardisation meetings or events to ensure a consistent approach to assessment. Undertake and record continuing professional development (CPD). Revision 2 October 2016 Page 24 of 46

25 B.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 and manufacturers recommendations. 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. B.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. Revision 2 October 2016 Page 25 of 46

26 SECTION C Administration and Certification C.1 Joining Instructions The OPITO-approved Assessment Centre must provide the candidate either with a copy of the OPITOapproved Blaster-Sprayer Competence Assessment Level 2 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. C.2 Validity and Renewal The Certificate is valid for 4 years. Therefore re-assessment of competence must be taken every 4 years for Blaster-Sprayers who wish to maintain their OPITO competence certification. Revision 2 October 2016 Page 26 of 46

27 C.3 Certification & Recording Persons successfully completing the competence assessment units in Level 2 will be issued with an OPITO-approved certificate for Blaster-Sprayer Competence Assessment Level 2. 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 Assessment Centres are responsible for issuing a certificate directly to candidates that have successfully completed Competence Assessment, and to the sponsoring company (when required), or if the candidate is unsuccessful, providing the candidate and candidate s employer with a written report identifying why the candidate was unsuccessful and suggest any further training requirement. Each certificate must indicate that the candidate has been assessed against and met the required standard. The certificate must 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. Revision 2 October 2016 Page 27 of 46

28 C.4 Administration Each delegate attending any OPITO approved programme must be registered with the Central Register (CR) operated by OPITO. Registration must be made by the OPITO-approved assessment centre to OPITO within one week following candidate s successful Level 2 assessment. 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/assessment records. At all times use of this data will be strictly in accordance with principles laid down in the UK Data Protection Act, Revision 2 October 2016 Page 28 of 46

29 Glossary of terms and abbreviations Terms ScaffTag Hold points 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. 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 MSDS MTDS PPE PTW RPE WAH Hand and Arm Vibration Syndrome Material Safety Data Sheet Manufacturers Technical Data Sheet Personal Protective Equipment Permit to Work Respiratory Protection Equipment Working at Height Revision 2 October 2016 Page 29 of 46

30 Appendix 1: Level 1 (WE) Logbook Workplace Experience Requirements For the candidate to become eligible to take the Level 2 Assessment, a fully completed and valid Level 1 (WE) logbook must be presented to the OPITO-approved Assessment Centre that are conducting the assessment, within two years from the completion date shown on the candidate s Level 1 Certificate. Each of the fourteen blaster/sprayer tasks specified below must be undertaken on different blasting/spraying operations and on different dates (where applicable) i.e. the candidate cannot get more than one task signed off on the same day. The Level 1 (WE) Logbook must record the following workplace experience: The candidate must undertake the following blaster/sprayer tasks under the supervision of a competent and experienced Blaster/sprayer: (1) Follow instructions of work pack including requirements of quality control plan; on five separate dates. (2) Degrease and fresh water-wash surfaces prior to carrying out mechanical preparation; on five separate dates. (3) Prepare structural steel surfaces to standard set in quality control plan by methods of mechanical preparation; on five separate dates. (4) Prepare pipe work to standard set in quality control plan by methods of mechanical preparation; on five separate dates. (5) Apply coatings to structural steel surfaces by brush meeting requirements set in client specification; on five separate dates. (6) Apply coatings to pipe work by brush meeting requirements set in client specification; on five separate dates. (7) Degrease and fresh water wash surfaces prior to carrying out abrasive blasting; on five separate dates (8) Prepare structural steel surfaces to standards set in quality control plan by methods of spot and sweep abrasive blasting; on five separate dates (9) Prepare pipe work to standards set in quality control plan by methods of spot and sweep abrasive blasting; on five separate dates (10) Prepare structural steel surfaces to standards set in quality control plan abrasive blasting method 100 % removal; on five separate dates. (11) Prepare pipe work to standards set in quality control plan abrasive blasting method 100 % removal; on five separate dates (12) Spray application of coatings to structural steel surfaces to the standards set in quality control plan; on five separate dates (13) Spray application of coatings to pipe work to the standards set in quality control plan; on five separate dates (14) Apply non slip coatings to deck areas; on three separate dates. Revision 2 October 2016 Page 30 of 46

31 Appendix 2: Practical Assessment Process The OPITO-approved Assessment Centre must confirm that that the candidate is eligible to undertake the Level 2 Assessment. The practical assessment will consist of the following: a) The candidate must be briefed to ensure he/she knows how the assessment will be conducted and what is expected of him/her during the assessment. b) The assessor must provide feedback to the candidate following completion of the practical assessments. Notes for the Assessor 1. An approved assessment checklist and record sheet must be used, and will be made available to the Assessor (Refer to Appendix 3) by the OPITO-approved Assessment Centre. Revision 2 October 2016 Page 31 of 46

32 Appendix 3: OPITO Level 2 Competence Assessment Record The following pages contain the Level 2 Assessor Checklists and the Assessment Record sheets. Although OPITO-approved Centres may develop their own versions of the Assessor Checklist and Competence Assessment Record, these must, as a minimum, include all the information contained in the Assessor Checklists and Competence Assessment Record sheets specified within this standard see next pages for the Assessor Checklist and Assessment Record. Checklist Notes Assessment Performance Criteria Checklist Reference numbers relate to Performance and Underpinning Knowledge and Understanding Criteria specified in each Unit. Assessment Underpinning knowledge and Understanding criteria The Assessor can infer Underpinning knowledge and Understanding by: (a) Observing the candidate performing the blasting/spraying task (b) Asking the candidate questions during the assessment (c) The candidate correctly answering the relevant questions from the written test (see Section A6). Checklist Abbreviations VQ Verbal Questioning OBS Observation WT Written Test Revision 2 October 2016 Page 32 of 46

33 OPITO Blaster-Sprayer Competence Assessment Level 2 Assessor Checklist Assessment Centre Assessment Centre Address Assessor Name Candidate Name Employer Name Element No 1.1 Contribute to effective working activities Ref No. Performance Criteria Achieved Y/N Comments An understanding of the main elements of typical: permits, client safe systems of work, VQ/OBS WT/S company procedures and risk assessments Interpreting MTDSs, client specifications and to decide on the appropriate blasting or coating method Conduct work according to a work pack with associated procedures and risk assessments How to contribute to a Tool Box Talk (TBT) Ability to work within a team Correct storage of equipment after use Ref No Assessor Signature Underpinning Knowledge and Understanding Criteria How to obtain relevant operational policies, procedures, instructions, codes of practice and standards Typical workplace reporting procedures relevant to the Blaster-Sprayer How to get specific information required for project records. Explain how Blaster-Sprayers typically request equipment, materials and PPE from a work scope. Achieved Y/N Assessment Date VQ/OBS WT/S Revision 2 October 2016 Page 33 of 46

34 OPITO Blaster-Sprayer Competence Assessment Level 2 Assessor Checklist Assessment Centre Assessment Centre Address Assessor Name Candidate Name Employer Name Element No 2.1 Maintain health and safety practices in the workshop Ref No. Performance Criteria Achieved Y/N Comments Ensure that personal protective equipment (PPE) is available for use, in good repair and VQ/OBS WT/S appropriately used Ensure tools/equipment are within specification and certification dates Record exposure time for HAVS records 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 Keep the work area as clean and tidy as possible Identify and report unsafe equipment Ref No Work safely in accordance with operational requirements and associated safe systems of work Underpinning Knowledge and Understanding Criteria Typical sources of safety information and safety observation systems of a site/ installation How to interpret a basic task-based risk assessment The use and care of various types of PPE & RPE related to Blaster-Sprayer operations Awareness of RPE tests and how often they should be done Typical hazards for blasting/painting activities Achieved Y/N VQ/OBS WT/S Revision 2 October 2016 Page 34 of 46

35 Assessor Signature The consequences of faulty or disconnected dead man units How and when to connect anti-static earth lines Typical precautions to take for working on live lines* Relevant elements of COSHH Assessment and how to interpret key points of a MSDS Appropriate communications methods when working as part of a team Typical problems associated with HAVS and the importance of recording exposure times Use of safe access equipment and platforms, and the Scafftag system Typical manual handling hazards and how mechanical lifting and handling aids can be used to overcome these Typical hazards associated with Blaster- Sprayer operations in confined spaces Typical methods for controlling Blaster- Sprayer-related risks in confined spaces Maintaining an emergency escape route from the work area What to do if an unsafe act/s was observed by the Blaster-Sprayer Assessment Date Revision 2 October 2016 Page 35 of 46

36 OPITO Blaster-Sprayer Competence Assessment Level 2 Assessor Checklist Assessment Centre Assessment Centre Address Assessor Name Candidate Name Employer Name Element No 2.2 Protect third party personnel, adjacent surfaces and the environment Ref No. Performance Criteria Achieved Y/N Comments Protect* adjacent surfaces, plant and equipment not being blast-cleaned or coated. VQ/OBS WT/S Protect prepared or painted work surfaces Ref No Assessor Signature Limit access to the area with appropriate signs and barriers. Ensure waste is limited by correctly following instructions for mixing ratios Underpinning Knowledge and Understanding Criteria How to obtain relevant operational policies, procedures, instructions, codes of practice and standards Typical workplace reporting procedures relevant to the Blaster-Sprayer How to get specific information required for project records. Explain how Blaster-Sprayers typically request equipment, materials and PPE from a work scope. Achieved Y/N Assessment Date VQ/OBS WT/S Revision 2 October 2016 Page 36 of 46

37 OPITO Blaster-Sprayer Competence Assessment Level 2 Assessor Checklist Assessment Centre Assessment Centre Address Assessor Name Candidate Name Employer Name Element No 3.1 Operate compressor equipment Ref No. Performance Criteria Achieved Y/N Comments Completing compressor familiarisation, prestart checks and correctly connecting VQ/OBS WT/S relevant equipment for the work Checking area in proximity of compressor air intake is clear Ref No Checking for foreign objects in the compressor case Correctly start up the compressor following relevant instructions or procedures Monitor compressor to ensure it is functioning properly during abrasive blasting or spray painting Shutting down compressor correctly and completing post-stop checks Underpinning Knowledge and Understanding Criteria Awareness of the different types of compressors applicable to Blaster-Sprayer operations and their applications Typical protection devices fitted to compressors How to shut down the compressor in an emergency Achieved Y/N The purpose and use of pre-start up checks VQ/OBS WT/S Typical hazards and precautions associated with multiple users sharing the same compressor Actions to be taken in the event of faults Revision 2 October 2016 Page 37 of 46

38 arising on the compressor Assessor Signature Assessment Date OPITO Blaster-Sprayer Competence Assessment Level 2 Assessor Checklist Assessment Centre Assessment Centre Address Assessor Name Candidate Name Employer Name Element No 4.1 Degrease and clean surfaces, and use correct power tools Ref No. Performance Criteria Achieved Y/N Comments Identify and correctly don appropriate PPE for mechanical preparation tasks VQ/OBS WT/S Degrease and clean surfaces in accordance with work pack* guidelines and procedures Correct use of mechanical power tools for surface preparation Ref No. Underpinning Knowledge and Understanding Criteria Achieved Y/N Reasons for correctly preparing a surface Assessor Signature The types of surfaces commonly treated by industrial Blaster-Sprayers The purpose of pre-cleaning the surface prior to conducting surface preparation. The consequences of applying coating to a surface that has not been correctly prepared. Assessment Date VQ/OBS WT/S Revision 2 October 2016 Page 38 of 46

39 OPITO Blaster-Sprayer Competence Assessment Level 2 Assessor Checklist Assessment Centre Assessment Centre Address Assessor Name Candidate Name Employer Name Element No 4.2 Prepare surfaces using abrasive blasting Ref No. Performance Criteria Achieved Y/N Comments Identify appropriate PPE for specific Blaster- VQ/OBS WT/S Sprayer tasks Correctly don PPE and ensure respiratory equipment is functional Install tear-offs on the blast hood Check equipment is in safe working order Load, monitor and maintain the supply of abrasive during the project Assemble blasting equipment correctly Monitor the air supply for any malfunction Use the appropriate technique to blast identified surfaces Ensure the visual surface preparation and blast profile are checked at agreed hold points Contain spent materials in a safe and secure manner Ensure that cleaned surfaces are to the required standard Shut down and make safe the blasting equipment Transfer used waste materials to the appropriate disposal site Reinstate the worksite in accordance with operation s requirements Underpinning Knowledge and Understanding Ref No. Criteria The importance of pre-shift checks of all blasting equipment for signs of deterioration or damage, to include: hoses, lines, joints and Achieved Y/N Revision 2 October 2016 Page 39 of 46

40 dead man handles Assessor Signature Factors affecting air quality supplied to blasting equipment and breathing air supplied to hoods The differences between dry grit blasting and wet slurry blasting Typical pressure-relief systems and components associated with blasting equipment Typical quality control checks on surfaces that have been abrasive blasted The consequences and control of flash rusting in the case of wet slurry blasting Assessment Date VQ/OBS WT/S Revision 2 October 2016 Page 40 of 46

41 OPITO Blaster-Sprayer Competence Assessment Level 2 Assessor Checklist Assessment Centre Assessment Centre Address Assessor Name Candidate Name Employer Name Element No 5.1 Prepare the work area and materials including appropriate tests Ref No. Performance Criteria Achieved Y/N Comments Conduct visual checks of work surfaces for contamination and defects; to include checks VQ/OBS WT/S for runs, sags, grit inclusion and overspray Prepare coatings to client specification by following the manufacturer s instructions Select and correct spray tip size needed for spraying different materials and surfaces Allow for the correct time between further coatings Ref No. Underpinning Knowledge and Understanding Criteria Achieved Y/N Typical types of coatings, to include: batch numbers and shelf life of the coatings Actions to take if experiencing unacceptable variations in environmental conditions The effects of working outside acceptable variations in environmental conditions Time allowance between coats Assessor Signature Symptoms, causes and corrections of common coating failures Assessment Date VQ/OBS WT/S Revision 2 October 2016 Page 41 of 46

42 OPITO Blaster-Sprayer Competence Assessment Level 2 Assessor Checklist Assessment Centre Assessment Centre Address Assessor Name Candidate Name Employer Name Element No 5.2 Apply coatings with brush (and roller when appropriate) Ref No. Performance Criteria Achieved Y/N Comments Identify and don appropriate PPE for specific hand painting application tasks Use the appropriate technique to stripe coat surfaces using a brush Use the appropriate technique to apply the coating using a brush and/or roller Ensure that coated surfaces are acceptable to the supervisor/inspector Check wet film thickness using a wet film gauge How to clean and store paint brushes and rollers Ref No. Underpinning Knowledge and Understanding Criteria Achieved Y/N Types of paint brushes/rollers and selecting the correct type for the application The reasons for stripe coating effectively Assessor Signature The purpose of conducting wet film thickness during application How to clean and store paint brushes and rollers Assessment Date Revision 2 October 2016 Page 42 of 46

43 OPITO Blaster-Sprayer Competence Assessment Level 2 Assessor Checklist Assessment Centre Assessment Centre Address Assessor Name Candidate Name Employer Name Element No 5.3 Apply coatings with spray paint Ref No. Performance Criteria Achieved Y/N Comments Don appropriate PPE and ensure respiratory equipment is functional Select the appropriate paint spraying equipment (including correct spray tip), for the task and ensure that it conforms to specific job requirements Identify the coatings suitable for the task Correctly assemble paint spraying equipment Correctly mix the paint Ref No Conduct checks on paint spraying equipment, compressed air equipment and pressurised lines to ensure they are in safe working order Monitor the hood and spray equipment air supplies and take appropriate action on any malfunction Load, monitor and maintain the supply of paint during operations Use the appropriate technique to spray surfaces to meet specifications Check wet film thickness using a wet film gauge Ensure that coated surfaces are acceptable to the supervisor/inspector Correct method of cleaning, shutting down and making safe the paint spraying equipment Underpinning Knowledge and Understanding Criteria The main differences between hood lines and paint spray lines Achieved Y/N Revision 2 October 2016 Page 43 of 46

44 Methods for applying non-slip coatings Assessor Signature How to check wet film thickness during application The purpose of surface cleanliness checks and how to perform them How to report defects and faults in equipment The consequences of not flushing out paint spray lines properly Awareness of other types of spraying equipment Hold points, and when to get sprayed coats checked Assessment Date Revision 2 October 2016 Page 44 of 46

45 OPITO Blaster-Sprayer (Level 2) Competence Assessment Candidate Full Name: Company: Standard Code: Role: Assessor Declaration: The Candidate was assessed against the competence assessment criteria specified in this Blaster-Sprayer Workplace Competence Standard. The Candidate named above *has / has not achieved a level of competence to enable him/her to be deemed competent against the performance and knowledge criteria. *I recommend that the candidate named requires further training and development specified below. * 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. Revision 2 October 2016 Page 45 of 46

46 Revision 2 October 2016 Page 46 of 46

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