| UCAR Safety Manual
 Respirators
REFERENCE: Respiratory Protection
ISSUED: 15 November 95
EFFECTIVE: 15 November 95
SUPERSEDES: none
Respiratory Protection Program
1.0 Scope
Provides safe practices, procedures and policies for the use of respiratory protection. Complies with Occupational Safety and Health Administration (OSHA) requirements 29 CFR 1910.134.
2.0 Definitions
2.1 Air-Purifying Respirator
A respirator in which ambient air is passed through an air-purifying element that removes the contaminant(s). It does not provide oxygen!
2.2 Assigned Protection Factor
The expected workplace level of respiratory protection provided by a properly functioning respirator to properly fitted and trained users.
2.3 Canister/Cartridge
A container with a filter, sorbent, catalyst, or combination of these items, which removes specific contaminants from the air passed through the container.
2.4 Negative Pressure Fit Check
A check to determine that a respirator is properly sealed to the face. The wearer covers the canister/cartridge openings with the palm of the hand, inhales gently and holds their breath for approximately 10 seconds. If properly sealed to the face, the facepiece should collapse slightly with no inward leakage of air.
2.5 Positive Pressure Fit Check
A check to determine that the respirator is properly sealed to the face. The wearer covers the exhalation valve with the palm of the hand, exhales gently. If properly sealed to the face, slight positive pressure will build up inside the facepiece without detecting any outward leakage of air.
2.6 Qualitative Fit Test
A pass/fail fit test that relies on the subject's sensory response to detect the challenge agent.
2.7 Quantitative Fit Test
A fit test using an instrument to measure the challenge agent inside and outside the respirator.
2.8 Respiratory Protection Program Administrator (RPPA)
The Safety and Site Services Director serves as the RPPA and as technical supervisor for respirator users.
2.9 Self Contained Breathing Apparatus (SCBA)
An atmosphere-supplying respirator in which the respirable gas source is carried by the wearer.
3.0 Responsibilities
3.1 Management
Assures
- adequate and suitable respirators are provided when necessary to protect the employee;
- employees are permitted to leave the hazardous area for any respirator-related cause including: failure of the respirator to provide adequate protection, malfunction of the respirator, increase in resistance of respirator during breathing, severe discomfort in wearing the respirator, illness of the respirator wearer, to wash his/her face and the respirator facepiece to minimize skin irritation, to exchange the respirator, to take periodic breaks in an uncontaminated area;
- respirator malfunctions are investigated and corrective measures are taken;
- respirator wearers are adequately trained to use and maintain their respirator.
3.2 UCAR Safety and Site Services Manager
Serves as the Respiratory Protection Program Administrator who
- estimates the concentration of an airborne contaminant in the work area prior to respirator selection and periodically during respirator use to ensure that the proper type of respirator is being used,
- selects the appropriate type of respirator for each contaminant present or anticipated,
- maintains records and written procedures that document the respirator program and allows for the evaluation of the program's effectiveness,
- evaluates the respiratory protection program's effectiveness annually,
- assures respirator wearers are properly trained and medically evaluated before using respirators,
- develops written standard operating procedures for the proper use and maintenance of respirators,
- conducts or supervises the fit testing of respirators,
- acts as technical supervisor for respirator use, (9) provides appropriate corrective lenses/spectacles when needed to be worn with a full face respirator.
3.3 Employees
- Wear respirators in accordance with instructions and training received,
- protect the respirator from damage,
- report to the RPPA any malfunctions of the respirator immediately,
- report to the RPPA any change in medical status that may impact their ability to wear a respirator safely,
- must be clean shaven when wearing an air-purifying respirator,
- maintains control of their individually issued respirator so that other employees do not use it.
4.0 General Principles
Respirators used by UCAR employees are NIOSH certified air-purifying respirators or self contained breathing apparatus (SCBA). They are used when engineered controls or materials substitution cannot provide adequate protection for employees. Proper respirator use is assured by the successful implementation of respirator procedures contained in this document.
5.0 Procedures
This section describes how employees obtain, wear, maintain, store and exchange air purifying and SCBA respirators. In this section, "respirator" refers to air-purifying and SCBA respirators.
5.1 Obtain a Respirator
Respirators are issued by the UCAR Safety and Site Services Manager after review of medical qualifications, training, and the work environment. Contact him/her to arrange for a time to meet.
5.2 How to Wear the Respirator
- Inspect the respirator to assure the facepiece is clean and free from damage, the inhalation and exhalation valves are in place, the straps can be adjusted, and the cartridges/canister are secure.
- Don the respirator as instructed during the training session. The respirator should fit snugly, but should not be painful or distort the face-to-facepiece seal.
- Perform positive and negative pressure fit checks. Adjust the respirator as necessary to pass the fit checks.
- Wear the respirator to perform work in accordance with training. Should there be any indication that the respirator is not providing protection, leave the work area and report to the RPPA.
5.3 Maintain the respirator
After each use, clean the respirator using packaged wipes. Inspect the respirator for defects while cleaning.
5.4 Store the Respirator
Store the respirator in a plastic bag where it will not be crushed by heavy objects, remains clean, and away from direct sunlight. Do not store respirators in tool boxes, lockers or desk drawers, unless they are protected from contamination, distortion and damage. SCBA's are stored in a carrying case.
5.5 Exchange the Respirator
Return the respirator to the RPPA when the respirator is no longer needed, requires maintenance beyond that performed by the employee, or is defective.
6.0 Administrative Requirements
Includes medical qualification, training, fit testing, monitoring use, monitoring hazards, respirator selection, recordkeeping and program review.
6.1 Medical Qualification
A physician shall determine whether or not an employee has any medical conditions that would preclude the use of respirators. The RPPA shall advise the physician of the types of respirators the employee will use; typical work activities, environmental conditions, frequency and duration of respirator use; and hazards for which the respirator will be worn.
6.2 Training
Each respirator user will be trained on the reasons for respirator use; the function, capabilities and limitations of the selected respirator; the proper wearing of the respirator; respirator maintenance, inspection and storage; recognizing and handling emergency situations; and applicable governmental regulations for specific substances, conditions, and respirator use.
6.3 Fit Testing
Qualitative or quantitative fit testing may be performed. Typically, the qualitative method will be used. Qualitative fit testing uses irritant smoke tubes. It consists of donning the respirator, conducting negative and positive pressure checks, and performing a series of exercises in the presence of an irritant smoke. If the respirator does not fit, the employee will cough. The respirator may be adjusted and the test repeated. If the test is not successful, another respirator will be selected.
6.4 Monitoring Use
The RPPA shall periodically monitor the use of respirators. This shall be done to determine that respirators are worn, maintained and stored as required. The RPPA should also confirm that the proper respirator is selected for the job.
6.5 Monitoring Hazards
Before a respirator is issued and periodically during its use, the program administrator shall monitor the respiratory hazard. Monitoring may consist of collecting air samples, estimating concentrations by calculations, or by comparison to similar conditions where air sampling was previously done or described in professional literature.
6.6 Respirator Selection
Respirator selection involves reviewing each operation to determine what respiratory and other safety hazards may be present and selecting the type of respirator that can offer adequate protection. Hazard determination is as follows: determine what contaminants and concentrations may be present; determine the Threshold Limit Value or other estimate of toxicity of the contaminants; consider the potential for oxygen deficient or Immediately Dangerous to Life or Health (IDLH) environment; determine whether the contaminant can be absorbed through the skin; determine if an odor, taste or irritation threshold exists for the contaminant; and select a respirator with an assigned protection factor appropriate for the airborne concentration, and a cartridge/canister type appropriate for the type of contaminant. An assigned protection factor table is found in Section 7.
6.7 Recordkeeping
Records of program elements will be maintained and include medical review; fit testing and training; details of test method, types of respirators tested, and the results of the tests; hazard evaluation; the annual audits and actions taken to correct shortcomings found during the audit.
6.8 Annual Audit
An annual audit shall be conducted to ensure that the program procedures reflect the requirements of current applicable regulations and industry accepted standards, and that program implementation reflects the written procedures.
7.0 Miscellaneous
7.1 Contractor Programs
Contractors are required to submit written respiratory protection programs to the RPPA for review and approval prior to using respirators for UCAR contracted work.
7.2 Respirator Maintenance
Respirators are cleaned and sanitized following manufacturers' instructions by an experienced person using parts designed for the respirator. Typically this will include: removal of cartridges or canisters, and other components recommended by the respirator manufacturer; washing the facepiece in warm water with cleaner/sanitizer solution; and thoroughly rinsing the respirator in clean, warm water. The respirator may air-dry or be hand-dried with a clean, lint-free cloth. Reassemble the respirator, replacing cartridges/canister as necessary. Inspect the respirator for defects while performing maintenance.
7.3 Self Contained Breathing Apparatus Maintenance
SCBAs are fully inspected and maintained following manufacturers' instructions. All maintenance beyond cleaning the facepiece and filling the cylinder is performed at a manufacturers' authorized service center. Grade D air is the minimum air quality provided .
7.4 Training
The following information is provided to assure respirators are worn properly and provide the necessary protection.
7.4.1 The type of respiratory hazard present.
7.4.2 The signs and symptoms of exposure.
7.4.3 How to report respirator problems.
7.4.4 Characteristics of the contaminant including smell, taste, irritation, or other indicators before a harmful concentration is reached.
7.4.5 The operation, capabilities and limitations of the selected respirator.
7.4.6 The proper way to inspect and don the respirator following manufacturers' instructions.
7.4.7 How to maintain and store the respirator.
7.4.8 Emergency procedures.
7.4.9 The OSHA regulations concerning the general use of respirators. Other specific standards containing respirator requirements. A copy of these standards is available from the RPPA as requested.
7.5 Respirator Qualitative Fit Testing
Following training, the employee dons a respirator and wears it for enough time to assure a comfortable fit. Irritant smoke is introduced around the sealing surface for the duration of the fit test. The employee is instructed to perform a series of exercises, each lasting approximately 30 seconds: normal breathing, deep breathing, smile, frown, cough, turn head from side to side, move head up and down, recite the alphabet, and normal breathing. If, at any time, the employee coughs from exposure to the irritant smoke, the test is suspended. The test may resume following successful adjustment of the respirator. The qualitative fit test is successfully completed if there is no cough from exposure to the irritant smoke.
7.6 Assigned Protection Factors
(extracted from ANSI Z88.2-1992):
Type of Respirator
Half Mask
Full facepiece
Air purifying
10
100
SCBA - <10,000
Reviewed by: Date:
RPPA:
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