TECHNOLOGY GUIDE NO. 12

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1 SSPC: The Society for Protective Coatings TECHNOLOGY GUIDE NO. 12 Guide for Illumination of Industrial Painting Projects SSPC-Guide Scope 1.1 This guide provides information on the quantity and quality of lighting on industrial painting projects that is conducive to achieving quality surface preparation and coating application, productivity, inspection/quality control, and accident prevention. 1.2 This guide is intended for use by facility owners, specifiers, designers, and contractors. 2. Background 2.1 Lighting standards have been established for most industrial applications by the American National Standards Institute (ANSI). One standard addresses the temporary lighting conditions common to most industrial painting projects. ANSI Z117.1, Safety Requirements for Working in Tanks and Other Confined Spaces, establishes minimum requirements for safe entry, continued work in, and exit from tanks and other confined spaces. The ANSI standard sets entry procedures which include the use of a permit to authorize illumination of the space. No specific criteria on illumination are stated. 2.2 Adequate illumination improves productivity and motivation while poor illumination increases the risk of accidents and costs of operation. Additional illumination beyond recommended levels may be beneficial but not essential to achieving these objectives. In addition, unnecessarily high lighting levels add to the cost of procurement, installation, and maintenance and may have a negative impact on safety and productivity due to increased glare. Light with substantial color bias, regardless of foot candles, can hinder the observation of the true condition of the work surface. 2.3 While natural lighting or use of white containment materials may provide adequate levels of illumination, once the decision to use artificial lighting to illuminate a work area is made, portions of the National Fire Protection Association (NFPA) and Occupational Safety and Health Administration (OSHA) regulations on portable lamps and wiring installation have direct application. However, an integrated guide specific to the coatings industry is necessary to help establish minimum standards on quality and quantity of light, as well as consolidate applicable electrical hazard controls. 2.4 Refer to any and all appropriate sections which pertain to portable lamps: NFPA 70, National Electric Code and OSHA regulations 29 CFR Sections The recommended levels of illumination contained in this guide are a result of both objective and subjective examination of lighting conditions in a variety of work spaces: tanks, containments, blast and paint rooms, shop floors, and other situations where similar conditions exist. The resulting lighting recommendations are believed to be comfortable for the workers, contributing to distortion-free work surfaces and adequate levels of illumination for performing general surface preparation, painting and inspection activities in the work space. Natural lighting, artificial lighting, or a combination of the two may be used to achieve the levels specified in this guide. 3. Referenced Standards 3.1 AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI) STANDARDS: RP7 Practice for Industrial Lighting Z117.1 Safety Requirements for Confined Spaces 3.2 FEDERAL SPECIFICATIONS AND STANDARDS: Code of Federal Regulations Title 29, Chapter XVII, Occupational Safety and Health Administration (OSHA): Part 1910 Occupational Safety and Health Standards, Subpart J--General Environmental Controls 29 CFR Permit-required confined spaces Part Safety and Health Regulations for Construction, Subpart K- Electrical, Installation Safety Requirements 29 CFR Applicability 29 CFR General requirements 29 CFR Wiring design and protection 29 CFR Wiring methods, components, and equipment for general use 29 CFR Specific purpose equipment and installation 29 CFR Hazardous (classified) locations 29 CFR Special systems 29 CFR Definitions applicable to Subpart K Electrical 3.3 NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) STANDARDS: 70 National Electric Code 1

2 3.4 UNDERWRITERS LABORATORIES (UL) STANDARDS, ANSI APPROVED: 298 Standard for Portable Electric Hand Lamps 1598 Standard for Luminaries (replaces all below) 4. Definitions Confined space: Per 29 CFR , a confined space is a space that: (1) is large enough and so configured that an employee can bodily enter and perform assigned work; and (2) has limited or restricted means for entry or exit (for example, tanks, vessels, silos, storage bins, hoppers, vaults, and pits are spaces that may have limited means of entry); and (3) is not designed for continuous occupancy. Foot candles: A unit of illumination; the illumination at a point on a surface which is one foot from, and perpendicular to, a uniform point source of one candle. General work area lighting: The level of illumination throughout a work area, measured at various locations on the horizontal work plane, at least six feet from the nearest light source. Non-permit required confined space: A confined space that does not contain or, with respect to atmospheric hazards, have the potential to contain any hazard capable of causing death or serious physical injury. Permit required confined space: A confined space that has one or more of the following characteristics: (1) contains or has the potential to contain a hazardous atmosphere; (2) contains a material that has the potential for engulfing an entrant; (3) has an internal configuration such that an entrant could be trapped or asphyxiated by inwardly converging walls or by a floor which slopes downward and tapers to a smaller cross-section; or (4) contains any other recognized safety or health hazard. Task-specific lighting: The level of illumination required for performing specific visual tasks (e.g., inspection). White light: Light containing all wavelengths in the visible range at similar intensity. 5. General Conditions 5.1 MONITORING STRATEGY Quantity of Existing (Natural) Light: Some natural light will be present in most work areas during daylight hours and the color of any containment materials (e.g., white tarps) may improve natural light. The amount of natural light will depend on factors such as time of year, time of day, orientation of the work area, and prevailing weather conditions. Although it is not likely that the quantity and quality of natural light will be sufficient for work in most confined spaces, the amount of additional lighting necessary to meet the recommendations of this guide will be affected by the amount of ambient natural light available. Measurements should be made with a light meter held at or placed on the surface. With the sensor aligned perpendicular to the surface, make a minimum of five measurements which are representative of the work area. Record each and calculate the average of the measurements Effect of Airborne Dust: Airborne dust will reduce visibility. Consideration must be given to the amount of loose debris which may be created during paint removal or application operations. Depending on the expected concentration of airborne dust, provisions may be required for its removal prior to the start of work in order for adequate illumination to be achieved. 5.2 CLASSIFICATION OF LOCATIONS: Once the evaluation of the work area is complete the work locations should be classified as one of the following: Hazardous locations where the potential for explosion and/or fire exists. Hazardous locations are defined as those locations where quantities of flammable gases or vapors, explosives, combustible dusts, fibers, or flyings are present or likely to become present. Lighting fixtures used in hazardous locations must be explosion proof and Underwriters Laboratory or Factory Mutual approved for use in the appropriate Class and Division atmosphere. See Appendix A for a discussion of hazardous locations Non-Hazardous locations where the potential for explosion and/or fire does not exist. Lighting fixtures used in nonhazardous locations must be designed to UL Standard Wet locations where installations are underground or in concrete slabs or masonry in direct contact with the earth, and locations subject to saturation with water or other liquids, such as unprotected locations exposed to weather. Lighting fixtures used in wet locations must be designed to UL Illumination Requirements 6.1 A light meter with readings in foot candles should be used to verify the adequacy of the illumination. For general work area measurements, the meter should be placed on a horizontal plane parallel with the work surface (e.g., walking across staging). For task specific measurements, the meter should be held at, or placed on, the surface, with the sensor aligned perpendicular to the surface. Make a minimum of five measurements representative of the work area or task. Compare the average to the criteria in Table 1 and Table Recommendations The recommendations below are applicable for any artificial lighting required to achieve adequate illumination of a given work area or specific task. 2

3 7.1 ALL LOCATIONS All lighting equipment must be durable and designed for the intended work environment Portable lamps and fixtures should be encased in a nonconductive, shatterproof material, which serves as an electrical insulator providing additional protection from electrical shock, abrasion, and corrosion resistance. Lamps and fixtures should also be equipped with substantial guards to prevent contact with personnel, containment materials, etc Use only heavily insulated cable with an abrasive resistant casing, at least gage 14/2 SO AWG or heavier and designed for hard or extra-hard usage, per NFPA 70 (e.g., types S, ST, SO, STO) Use of white light is recommended, as it is closest to natural light. White light does not visually distort the surface being worked on or being inspected. Lighting equipment capable of providing white light should be selected for task specific lighting where practical. 7.2 NONHAZARDOUS, WET LOCATIONS: All lighting fixtures having an electrical supply service greater than 12 volts must be properly grounded, have ground fault circuit interrupter (GFCI) protection, or have an integrated circuit breaker wired into the specific electrical line supplying the power to the light fixture. 8. Proper Use and Maintenance of Lighting Equipment 8.1 LIGHTING FIXTURES All lighting systems should be removed from the direct spray of paint, abrasives, or other materials. Impacts of air flow patterns from any ventilation system in operation should also be considered. Paint overspray with accumulations on fixtures reduces the amount of light emitted and restricts heat dispersement of the light, which may cause premature failure or overheating Do not tape over the lens or cover areas designed for heat dispersement, as this may cause severe damage to the fixture and significantly reduces bulb life Do not drop or drag lighting fixtures. 8.2 POWER CORDS AND CONNECTORS Periodically inspect GFCIs, plugs, integrated circuit breakers, and power cords, as well as all power cord connections. TABLE 1 WORK AREA ILLUMINATION REQUIRMENTS IN FOOT CANDLES 1 Minimum Recommended General Work Area Task specific - surface preparation and coating application Task specific - inspection Based upon levels of illumination recommended for sample occupational tasks in ANSI/IES RP 7. 2 The level of illumination throughout a work area, measured at various locations on the horizontal work-plane, at least 6 feet (2 m) from the nearest light sources. (See Section 6.1). An illumination level of 20 foot candles is recommended for corridors, scaffolds, and other walking surfaces. 3 The level of illumination for performing specific visual tasks (i.e., surface preparation, coating application, and inspection) measured at the work surface in conjunction with the intended light source (See Section 6.1) TABLE 2 MAXIMUM LUMINANCE RATIOS 1 Between task and adjacent darker surroundings 2 5 to 1 3 Between task and adjacent lighter surroundings 1 to 5 1 Maximum luminance ratios recommended are based upon areas (indoor or outdoor) where it is completely impractical to control reflectances and difficult to alter environmental conditions. 2 The eyes function more efficientlly and comfortably when the illumination levels within the work environments are not too different from those of the seeing task. 3 Based upon maximum luminance ratios from ANSI/IES RP 7 3

4 8.2.2 Do not modify or otherwise alter connectors. Use an outlet that is compatible with the connector Immediately replace or repair any device or cable that appears to be worn or broken. 8.3 REPAIRS Disconnect power and remove any lights or electrical apparatus needing repair outside any hazardous atmosphere before performing repairs All connections, seals and assemblies must be repaired per the manufacturer s instructions, using the manufacturer s recommended parts Parts for repair other than those specified by the manufacturer of the lighting system should not be used Replacement bulbs other than those specified by the manufacturer of the lighting system should not be used. 9. Disclaimer This material has been developed under the published procedures of SSPC: The Society for Protective Coatings, which has been designed to assure the appointment of technically competent committees having balanced representation. While these procedures assure the highest degree of care, neither SSPC, its members, nor those participating in its activities accept any liability resulting from compliance or noncompliance with the provisions given herein, for any restrictions imposed on materials or processes, or for the completeness of the text. SSPC has no power or authority to police or enforce compliance with the contents of this document, and any certification of products stating compliance with requirements of this document is made at the peril of the certifier. 10. Notes 10.1 Air cooled lighting systems, which direct the flow of compressed air across the lens or around the globe, help to keep the lens free of contaminants, prolong bulb life, and generally are of higher intensity required for the lighting of areas with high concentrations of airborne dust OTHER PERTINENT STANDARDS: Other industry standards which may be pertinent for illumination in industrial painting projects are listed below National Fire Protection Association (NFPA) Standards: 70E Standard for Electrical Safety Requirements for Employee Workplaces 77 Recommended Practice on Static Electricity 497 Recommended Practicenfor the Classification of Flammable Liquids, Gases, orvapors, and of Hazardous (Classified)Locations for Electrical Installations in Chemical Process Areas. 654 Standard for Prevention of Fire and Dust Explosions from the Manufacturing, Processing, and Handling of Combustible Particulate Solids Underwriters Laboratories (UL) Standards, ANSI Approved: 781 Standard for Portable Electric Lighting Units for Use in Hazardous (Classified) Locations Appendix A. Explosion Hazards A. 1 BACKGROUND Achieving acceptable levels of illumination by natural or artificial means in the industrial painting industry is complicated due to the complexity of structures, vision inhibiting dust, and potentially hazardous concentrations of explosive dust or solvent vapors. This appendix has been added to provide some direction, but is not considered a requirement of this guide. A. 2 DEFINITIONS Hazardous locations are classified as Class I, Class II, or Class III depending upon the physical properties of the substances which are present. These classes are further subdivided as Division 1 or Division 2. Class I locations: Class I locations are those in which flammable gases or vapors are or may be present in the air in quantities sufficient to produce explosive or ignitable mixtures. Class I locations include the following: Class I Division 1: A Class I Division I location is a location (a) in which hazardous concentrations of gases or vapors may exist under normal operating conditions or (b) in which hazardous concentrations of such gases or vapors may exist frequently because of repair or maintenance operations or because of leakage or (c) in which breakdown or faulty operation of equipment or processes might release hazardous concentrations (e.g., greater than 10% of the Lower Explosive Limit) of flammable gases or vapors and might also cause simultaneous failure of electric equipment. Class I, Division 2: A Class I, Division 2 location is a location (a) in which volatile flammable liquids or flammable gases are handled, processed or used, but in which the hazardous liquids, vapors, or gases will normally be confined within closed containers or closed systems from which they can escape only in case of accidental rupture or breakdown of such containers or systems, or 4

5 in case of abnormal operations of equipment, or (b) in which hazardous concentrations of gases or vapors are normally prevented by positive mechanical ventilation, and which might become hazardous through failure or abnormal operations of the ventilation equipment, or (c) that is adjacent to a Class I, Division 1 locations and to which hazardous concentrations of gases or vapors might occasionally be communicated unless such communication is prevented by adequate positive pressure ventilation from a source of clean air, and effective safeguards against ventilation failure are provided. Class II locations: Class II locations are those that are hazardous because of the presence of combustible dust. Class II locations include the following: Class II, Division 1: A Class II, Division 1 location is a location: (a) in which combustible dust is or may be in suspension in the air under normal operating conditions, in quantities sufficient to produce explosive or ignitable mixtures; or (b) where mechanical failure or abnormal operation of machinery or equipment might cause such explosive or ignitable mixtures to be produced, and might also provide a source of ignition through simultaneous failure of electric equipment, operation of protection devices, or from other causes, or (c) in which combustible dusts of an electrically conductive nature may be present. Class II, Division 2: A Class II, Division 2 location is a location in which: (a) combustible dust will not normally be in suspension in the air in quantities sufficient to produce explosive or ignitable mixtures, and dust accumulations are normally insufficient to interfere with the normal operation of electrical equipment or other apparatus; or (b) dust may be in suspension in the air as a result of infrequent malfunctioning of handling or processing equipment, and dust accumulations may be ignitable by abnormal operation or failure of electrical equipment or other apparatus. Class III locations: Class III locations are those that are hazardous because of the presence of easily ignitable fibers or flyings (e.g., dust) but in which such fibers or flyings are not likely to be in suspension in the air in quantities sufficient to produce ignitable mixtures. Class III locations include the following: Class III, Division 1: A Class III, Division 1 location is a location in which easily ignitable fibers or materials producing combustible flyings are handled, manufactured, or used. Class III, Division 2: A Class III, Division 2 location is a location in which easily ignitable fibers are stored or handled, except in process of manufacture. Note: The above definitions of hazardous (classified) locations are taken directly from 29 CFR Refer to the OSHA standard for additional information and examples for each classification. Hazardous Atmosphere: An atmosphere that may expose employees to the risk of death, incapacitation, impairment of ability to self-rescue (that is, escape unaided from a permit space), injury, or acute illness from one or more of the following causes: (1) flammable gas, vapor, or mist in excess of 10 percent of its lower flammable limit (LFL); (2) airborne combustible dust at a concentration that meets or exceeds its LFL; (3) atmospheric oxygen concentration below 19.5% or above 23.5%; (4) atmospheric concentration of any substance for which a dose or a permissible exposure limit is published in subpart G, Occupational Health and Environmental Control, or in subpart Z, Toxic and Hazardous Substances, which could result in employee exposure in excess of its dose or permissible exposure limit; (5) any other atmospheric condition that is immediately dangerous to life or health. NOTE: This definition is taken directly from 29 CFR For the purposes of this guide, only those considerations in selecting lighting dealing with the concentrations of flammable vapors or combustible dusts [items (1) and (2) above] are addressed. The reader is cautioned to consider all other aspects of a hazardous atmosphere as described above. Lower Flammable Limit: The lower limit of flammability of a gas or vapor at ordinary ambient temperatures expressed in percent of the gas or vapor in air by volume. Lower Flammable Limit is synonymous with Lower Explosive Limit. A.3 EVALUATION OF WORK SITES: Before any aspect of an industrial painting project commences, the location must be evaluated to determine whether a hazardous atmosphere exists. This evaluation involves a thorough inspection of the work location and often includes both a visual inspection and monitoring for atmospheric hazards. OSHA s permit-required confined space standard (29 CFR ) requires that employers test and monitor spaces with instruments which detect all aspects of hazardous atmospheres that may be encountered. OSHA has classified atmospheric hazards into three categories: toxic; asphyxiating; and flammable or explosive atmospheres. Monitoring tests are typically performed using a direct reading instrument which gives an instantaneous assessment of the degree of atmospheric hazard. From a lighting perspective, the minimum required tests in any suspect hazardous atmosphere include oxygen level, the concentration of flammable gases or vapors, and the concentration of combustible dust. A.4 SURVEY CONSIDERATIONS: Initial testing for hazards may not be enough. Periodic or continuous testing may be required, as conditions can change and become hazardous during the painting project. Conditions may also vary throughout a work space. Concentrations of flammable gases and vapors may vary depending on their physical characteristics (i.e., heavier gases may tend to concentrate near the bottom of tightly sealed spaces while light gases may concentrate near their emission source or near the top of the space). With this in mind, a monitoring strategy must be developed which takes into account both the physical properties of potential atmospheric hazards and the physical characteristics of the structure. The instrumentation 5

6 used to monitor the atmosphere must be classified as intrinsically safe or Underwriters Laboratories (UL) or Factory Mutual (FM) approved for Class I, Division 1 atmospheres. A.5 HAZARDOUS LOCATIONS, CLASS I AND CLASS II A.5.1 Explosion proof lighting will be used whenever painting with a paint containing combustible solvents or performing any operation which introduces combustible compounds into a confined space. A.5.2 All explosion proof lighting fixtures used must be designed to comply with the requirements of NFPA 70. A.5.3 All related connectors must be rated in the same manner or be located outside the hazardous location/work space. 6

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