Specialist Hazard Control Solutions Kept Workers Safe From Paint Fumes During Navy Ship Repairs

Project Overview

During a major life-extending refit for a Type23 Frigate, one of the Royal Navy’s most versatile ships, the project almost stopped completely due to uncovering a risk which could have put dockyard workers at risk of exposure to harmful VOCs.

The goal was simple – solve the environmental challenges quickly and enable the customer to finish the refit and put the platform back to work.

Challenge

Two thirds of the outer hull had been painted, when an improvement notice was issued base-wide for the activity of spraying. It stated that improved controls would be needed for the extraction and filtration of the paint fumes, due to the possible ill-effects to those carrying out the activities and those working nearby. The previous system used was identified as inadequate.

At short notice, RVT was called upon to survey the space and to work with the Support Service Controller to understand the specific hazard, the environment and the work process. RVT then designed a control system to ensure VOCs were controlled within the space without migration elsewhere, ensuring the process could be finished safely.

Solution

The RVT Group recommended a hybrid solution of high-volume extraction and filtration using activated carbon cartridges. The Aft end of the ship was provided with extraction to atmosphere (outside of the complex an exclusion zone was created). All extraction equipment was ATEX rated.

RVT provided a total air movement of nearly 27,000m³ per hour, achieving 3.6 air changes in the entire space per hour. The dock bottom was effectively under a ‘negative pressure’ meaning that there was no way for fumes to escape the working area and migrate to other areas. RVT visited the project after the first coat of paint was applied, to ask for feedback. The Customer was extremely pleased with the result, which exceeded their expectations. When tested by their own Occupational Hygiene team during the works, they recorded a PPM measurement of 6PPM (Parts per million). The previous system used provided a best recording of 150PPM – a 96% reduction in harmful exposure!

The solution that RVT installed satisfied the health and safety requirements on the base and allowed the activity to go ahead within the customer’s deadline – overcoming a potentially catastrophic delay which would have been costly, because many workers would have been stood down, as well as the Ship not meeting its deadline for completion. Ultimately this set the standard for ship coatings and VOC control within the base, still used today. Further progress has been made to improve the outcomes during spraying activities, such as environmental controls to aid paint curing whilst working with the ventilation process. All of this was possible due to RVT’s onsite team, who played such an important part in solving the problem and managing the solution during the project.