Document 3ergD2rVZ6pJK4jOZn7g0LnGx

4 0 Engineering Standard ALCOA Materials and Standards Section Pittsburgh PLAINTIFFS EXHIBIT 18.1.1 PAGE 1 RESPIRATORY PROTECTION AL-260 1975-10 closing Alcoa's approach, and is not intended to be a recommendation Tor any recipient other than Alcoa. No warranties, guarantees or repre senlations. express or implied are made as to the u tility or effectiveness o f the methods, processes, products or procedures described or recommended herein. INDEX PAGE 1. Scope 2 2. Glossary of Terms 2 3. Program Administration 3.1 Objective 3.2 Alcoa Responsibility 3.3 Plant Administration 3.4 Employee Responsibility 3 3 3 3 3 4. Requirements of a Respiratory Protection Program 4.1 Procedures 4.2 Assessment of Work Atmosphere 4.3 Selection 4.4 Approved Respirators 4.5 Personal Use 4.6 Instruction and Training 4.7 Maintenance and Inspection 4.8 Storage 4.9 Program Evaluation 3 3 3 3 3 3 3 3 4 4 5. Classification of Respiratory Hazards 5.1 Hazards 4 4 6. Selection of Respirators 6.1 Requirements 6.2 Nature of the Hazard 6.3 Extent of Hazard 6.4 Work Requirements 6.5 Guide for Selection of Respirators 4 4 4 4 4 4 7. Description, Capacities and Limitations of- Respirators 7.1 Types of Respirators 7.2 Atmosphere-Supplying Respirators 7.2.1 Self-Contained Breathing Apparatus 7.2.2 Hose Masks 6 6 6 6 6 PAGE 7.2.3 Air-Line Respirators (Continuous Flow, Demand and Pressure- Demand Types) 6 7.2.4 Combination Self- Contained and Air- Line Respirators 7 7.3 Air-Purifying Respirators 7 7.3.1 Gas and Vapor Respirators 7 7.3.2 Particulate Respirators 8 7.4 Combinations of Gas and Vapor and Particulate Respirators 8 7.5 Gas Masks 8 8. Respirable Air and Oxygen 8.1 Specifications for Respirable Air and Oxygen 8.2 Compressed Air 8.3 Compressed Oxygen 8 8 8 8 9. Training and Education in Proper Use of Respiratory Protection Devices 9.1 Training and Education 9.2 Instructions for Use 9.3 Facepiece Fit Tests 9 9 9 9 10. Maintenance and Care of Respirators 9 10.1 Program 9 10.2 Respirator Inspection 10 10.3 Cleaning and Sanitizing 10 10.3.1 Methods of Cleaning and Sanitizing 10 10.3.2 Responsibility 10 10.4 Repair and Storage 10 11. Bibliography 11 This standard is lire properly o f Aluminum Company o f America and must he returned on request. It shall not be reproduced or copied, in whole or in part, or used ou beliair o f others than Aluminum Comparty o f America or its subsidiaries, w ithout permission. This engineering standard is provided solely for the purpose o f dis- ATC 00081 0 Engineering Standard ALCOA Materials and Standards Section Pittsburgh RESPIRATORY PROTECTION 18.1.1 PAGE 2 1973-10 1. SCOPE This standard sets forth accepted practices for respirator users. It provides information and guidance on the proper selection, use, and care of respirators. The standard conforms with regulations promulgated under the Occupational Safety and Health Act (OSHA) CFR 29, Section 1910.134, as published in the Federal Register of October 18, 1972. 2. GLOSSARY OF TERMS AIR CONTAMINATION LEVEL -- The standards of contaminant levels prescribed by the Secretary of Labor in accordance with the provisions of Section 1910.93 of the Occupational Safety and Health Act of 1970. AIR-LINE RESPIRATOR - An air-supplied respirator wherein respirable air is supplied to a respiratory-inlet covering by means of a small diameter hose connected to a positive pressure supply of respirable air. AIR-PURIFYING RESPIRATOR - A respirator designed to remove contaminants from ambient air prior to its inhalation. APPROVED RESPIRATOR - A respirator tested and listed as satisfactory by the Bureau of Mines, U. S. Department of the Interior, and the National Institute of Occupational Safety and Health, U. S. Department of Health, Education and Welfare. ATMOSPHERE-SUPPLYING RESPIRATOR - A respirator wherein the respirable atmosphere is supplied to the wearer from a source independent of the ambient air. EXHALATION VALVE - A device that allows exhaled air to be expelled from a respirator while preventing outside air from entering the respirator through it. FACEPIECE - A tight-fitting device that covers the wearer's nose and mouth making an airtight fit with his face and which may also cover his eyes. A head harness usually is included in the assembly of the facepiece. FILTER - A medium that removes particles from air passing through it. FULL FACEPIECE - A tight-fitting device that covers the wearer's nose, mouth, eyes and face and which makes an airtight fit with his face. A head harness usually is included in the assembly of the facepiece. FUME - Solids produced from physiochemical reactions such as combustion, sublimation, generally of metallic origin, and having individual sires well below one micrometer in diameter. HALF-MASK FACEPIECE - A tight-fitting device that covers the wearer's nose and mouth and which makes an airtight fit with his face. A head harness usually is included in the assembly of the facepiece. HEAD HARNESS - A device that holds a facepiece securely in place on the wearer's face. HELMET - A loose-fitting rigid device that covers the face or which may completely cover the head and neck and sometimes a portion of the shoulders. HOOD - A loose-fitting device of nonrigid construction that completely covers the head, neck, and portion of the shoulders. INHALATION VALVE - A device that allows respirable air to enter the respiratoryinlet covering of a respirator and which prevents air from leaving the covering through the intake part. MIST - A liquid condensation particle with sizes ranging from submicroscopic to visible or macroscopic. OXYGEN-DEFICIENT ATMOSPHERE - Ambient air having less than 19.5% by volume of oxygen. PARTICULATE MATTER - Finely divided solid or liquid particles. A suspension of particulate matter in air is commonly known as an aerosol. POWERED PARTICULATE-FILTER RESPIRATOR An air-purifying respirator that employs a blower to pass ambient air through a filter that removes particles and supplies respirable air to a respiratory-inlet covering. RESISTANCE - Opposition to the flow of air. RESPIRABLE DUST - A dust particle aerodynamically capable of reaching the terminal airways of the lung. RESPIRATOR - A device designed to protect the wearer from inhalation of harmful atmospheres. REUSABLE PARTICLE-FILTER RESPIRATOR - An air-purifying respirator which removes particles from ambient air prior to its inhalation and which is designed so that the filter may be replaced or cleaned and the respirator reused. SELF-CONTAINED BREATHING APPARATUS - An atmosphere-supplying respirator wherein a ATC 00082 closing Alcoa's approach, and is not intended to be a recommendation for any recipient other than Alcoa. No warranties, guarantees or repre sentations, express or implied arc made as to the u tility or effectiveness o f the methods, processes, products or procedures described or recommended herein. G3 Engineering Standard ALCOA Materials and Standards Section Pittsburgh RESPIRATORY PROTECTION 18.1.1 PAGE 3 1975-10 supply of air, oxygen or oxygen-generating material is carried by the wearer. The respirator provides respiratory protection in atmospheres immediately hazardous to life or health including atmospheres deficient in oxygen. SELF-RESCUE MOUTHPIECE RESPIRATOR - An air-purifying respirator designed for self-rescue from immediately dangerous atmospheres of gases and vapors. A nose clip is used to prevent nasal breathing. SHALL - Denotes a requirement. SHOULD - Denotes a recommendation. SINGLE-USE PARTICULATE-FILTER RESPIRATOR An air-purifying respirator which removes particles from ambient air prior to inhalation and which is designed to be discarded after a single use or after one day's use. VAPOR - The gaseous state of a substance that is solid or liquid at ordinary temperatures and pressures. 3. PROGRAM ADMINISTRATION 3.1 Objective. In the control of those occupational diseases caused by breathing air contaminated with harmful dusts, fogs, fumes, mists, gases, smokes, sprays or vapors, the primary objective shall be to prevent atmospheric contamination. This shall be accomplished as far as feasible by accepted engineering control measures (for example, enclosure or confinement of the operation, general and local ventilation,' and substitution of less toxic materials). When effective engineering controls are not feasible, or while they are being instituted, appropriate respirators shall be used. 3.2 Alcoa Responsibility. Respirators shall be provided by Alcoa when such equipment is necessary to protect the health of the employee. Respirators shall be applicable and suitable for the purpose intended. Where the use of respirators is required, a respiratory protective program shall be established which shall comply with the provisions of this standard. 3.3 Plant Administration. The plant safety and industrial hygiene personnel, in cooperation with the Medical Department, shall oversee the plant respiratory protection program. Specific responsibility for the program within a department shall be vested in one individual, the Departmental Coordinator, who will coordinate his efforts with similar appointees of other departments to meet the requirements of the overall plant respiratory protection program. 3.4 Employee Responsibility. The employee shall use the provided respiratory protection in strict accordance with instructions and training received. Also he will immediately report any malfunction of the respirator to the responsible person of his department. 4. REQUIREMENTS OF A RESPIRATORY PROTECTION PROGRAM 4.1 Procedures. Written standard operating ' procedures governing the selection and use of respirators shall be established. 4.2 Assessment of Work Atmosphere. Appropriate surveillance of work area conditions and degree of employee exposure shall be maintained. 4.3 Selection. Respirators shall be selected on the basis of hazards to which the employee is exposed. 44 Approved Respirators. Approved respirators shall be used when they are available. The respirator furnished shall provide adequate respiratory protection against the particular hazard for which it is designed in accordance with standards established by competent authorities. 4.4,1. Under OSHA regulations all respirators will eventually carry the approval of both the U. S. Bureau of Mines and the National Institute of Safety and Health' (NIOSH). It will be some time before manufacturers will obtain approvals under the current schedules. Until such times, the Bureau of Mines approvals under the older schedules shall be used. 4.5 Personal Use. Where a respirator is required to be used on a regular basis it shall be assigned to the employee for his exclusive use. 4.6 Instruction and Training. Employees shall be instructed and trained in the proper use and limitations of respirators. 4.7 Maintenance and Inspection. Respirators shall be regularly maintained m proper condition, cleaned and sanitized. Those issued to the employee for his exclusive use should be cleaned by him after each day's use, or more often if necessary. Those used on a one-time basis shall be returned to the cleaning station where they will be sanitized prior to reissue. Respirators used routinely shall be inspected during cleaning. Worn or deteriorated parts shall be replaced. Respirators for emergency use such as self-contained devices shall be thoroughly inspected at "least once a month and after each use. This standard is the properly o f Aluminum Company o f America and must he returned on request. It shall not be reproduced or copied, in whole or in part, or used on behalf o f others than Aluminum Compuny of America or its subsidiaries, w ithout permission. I his engineering standard is provided solely for the purpose o f dis- *TC 00083 0 Engineering Standard ALCOA Materials and Standards Section Pittsburgh RESPIRATORY PROTECTION 18.1.1 PAGE A 1973-10 4.B Storage. Respirators shall be stored in a convenient and clean location. 4.9 Program Evaluation. There shall be regular evaluation by the Departmental Coordinator to determine the continued effectiveness of the program. 5. CLASSIFICATION OF RESPIRATORY HAZARDS 5.1 Hazards. Respiratory hazards for the purpose of this standard are classified as follows: 1. Oxygen deficiency 2. Gas and vapor contaminants a. Immediately dangerous to life or health b. Not immediately dangerous to life or health 3. Particulate contaminants a. Immediately dangerous to life or health b. Not immediately dangerous to life or health 6. SELECTION OF RESPIRATORS 6.1 Requirements. When there is doubt about the concentration of oxygen or hazardous material present in the atmosphere, only those respirators listed as suitable in oxygen deficient environments shall be used. Any erring in the selection of respirators shall be on the safe side. The selection of a proper respirator for any given situation requires consideration of the following factors: 1. Nature of the hazard {Section 6.2) 2. Extent of the hazard (Section 6.3) 3. Work requirements and conditions (Section 6.4) 4. Characteristics and limitation of available respirators (Section 7) 6.2 Nature of the Hazard. The chemical and physical properties, toxicity and concentration of the hazardous material shall be considered in respirator selection. Evaluation of the atmospheric contaminant concentration to which a person wearing a respirator may be exposed is an integral part of an effective respirator program. Air sampling data are important in the selection of the proper respirator and should include the identification, toxicity and concentration of the contaminant in the breathing zone. In an air monitoring program, sampling should be carried out over at least one cycle of operation and, preferably, over several cycles when production activity varies. Normally, samples are collected at the worker's breathing zone. 6.3 Extent of Hazard. The extent of the hazard in space and time and its physical location shall be considered in respirator selection. This includes the length of time protection will be needed, entry and exit times, accessibility of a fresh air supply, and the ability to use air lines or move about freely while wearing the respirator. The location of the contaminated area in respect to a possible source of respirable air requires consideration. 6.4 Work Requirements. Work time usually determines the length of time for which respiratory protection is needed, including the time necessary to enter and leave a contaminated area. A self-contained breathing apparatus or chemical-cartridge respirator provides respiratory protection for relatively short periods, whereas the hose mask with blower, air-line respirator, and abrasive-blasting respirator provide protection for as long as the facepiece is supplied with adequate respirable air. Particulate-filter respirators can provide protection for long periods, without need for filter replacement, only if atmospheric particulate loading is low. Where particulate concentrations are high, the filter will quickly load up, resulting in an intolerably high pressure drop. Therefore, for extended periods of use, the hose mask with blower and air-line respirators offer definite advantages. Experience has demonstrated that not all persons can obtain a satisfactory facepieceto-face seal with air-purifying respirators. Therefore, to provide an adequate facepieceto-face seal on a variety of facial features, it may be necessary that two or more models of respirators be available. When an individual can be fitted with two or more respirators, he should be permitted to select the most comfortable one. 6.5 Guide for Selection of Respirators. Table 1 is a quick reference for the selection of respiratory protection appropriate to the type and degree of hazard. The Table provides minimal guidance, however, and shall be used along with" other information from this standard and from the respirator manufacturers. -rr. 0008A closing Alcoa's approach, and is not intended to be a recommendation for any recipient other than Alcoa. No warranties, guarantees or repre sentations, express or implied are made as to the u tility or effectiveness o f the methods, processes, products or procedures described or recommended herein. Engineering Standard ALCOA Materials and Standards Section Pittsburgh RESPIRATORY PROTECTION 18.1.1 PAGE 5 1975-10 TABLE 1 GUIDE FOR SELECTION OF RESPIRATORS Hazard Resoirator Oxygen Deficiency Self-contained breathing apparatus. Hose mask with blower. Combination air-line respirator with auxiliary self-contained air supply or an air-storage receiver with alarm. Gas and Vapor Contaminants Immediately dangerous to life or health Self-contained breathing apparatus. Hose mask with blower. Self-rescue mouthpiece respirator (for escape only) Combination air-line respirator with auxiliary self-contained air supply or an air-storage receiver with alarm. Not immediately dangerous to life or health Air-line respirator. Hose mask without blower. Air-purifying half-mask respirator with chemical cartridge. Particulate Contaminants immediately dangerous to life or health Self-contained breathing apparatus. Hose mask with blower Air-purifying full facepiece respirator with appropriate filter. Self-rescue mouthpiece respirator (for escape only) Combination air-line respirator with auxiliary self-contained air supply or an air-storage receiver with alarm. Not immediately dangerous to life or health Air-purifying half-mask respirator with filter pad or cartridge. Air-line respirator. Air-line abrasive-blasting respirator. Hose mask without blower. Combination Gas, Vapor, and Particulate Contaminants Immediately dangerous to life or health Self-contained breathing apparatus. Hose mask with blower. Self-rescue mouthpiece respirator (for escape only) Combination air-line respirator with auxiliary self-contained air supply or an air-storage receiver with alarm. Not immediately dangerous to life or health Air-line respirator. Hose mask without blower. Air-purifying half-mask respirator with chemical cartridge and appropriate filter. Note 1: For details on use of respirators in hazardous atmospheres and for descriptions, capabilities and limitations of respirators, refer to Section 7. This standard is the properly o f Aluminum Company o f America and must be returned on request. It shall not be reproduced or copied, in whole or in part, or used on behalf o f others than Aluminum Company o f America or its subsidiaries, w ithout permission. Ibis engineering standard is provided solely for the purpose o f clis- ATC 00085 0 Engineering Standard ALCOA Materials and Standards Section Pittsburgh RESPIRATORY PROTECTION 18.1.1 PAGE 6 1973-10 7 DESCRIPTION, CAPACITIES AND LIMITATIONS OF RESPIRATORS 7.1 Types of Respirators. The purpose of this section is to provide a description of the various types of respirators, their limitations and capacities for subsequent selection of suitable respiratory protection. Respirators fall into the following class ification according to mode of operation: 1. Atmosphere-supplying respirators a. Self-contained b. Hose-mask c. Air-line d. Combination self-contained and hose-mask or air-line 2. Air-purifying respirators a. Chemical cartridge - for gas and vapor contaminants b. Filter - for particulate contaminants c. Combination filter and chemical cartridge - for combination gas, vapor and particulate contaminants 3. Gas masks 7.2 Atmosohere-Suoplving Respirators. Atmosphere-supplying respirators provide protection against oxygen deficiency and most toxic atmospheres. The breathing atmosphere is independent of ambient atmospheric conditions. Section 8 details the specifications on respirable atmospheres of air and oxygen. Except for the supplied-air suit, no protection is provided against skin irritation or against sorption of materials through the skin. 7.2.1 Self-Contained Breathing Apparatus. The self-contained breathing apparatus has no limitation as to the concentration of gaseous or particulate contaminants in which it may be worn and use is permissible in atmospheres immediately dangerous to life. Since the wearer carries his own supply of respirable atmosphere with him, he may leave the work area through any available exit. The period over which the device will provide protection is limited by the amount of air in the apparatus, the ambient atmospheric pressure (service life is cut in half by a doubling of the atmospheric pressure), and work load. A warning device shall be provided to indicate to the wearer when the service life has been reduced to a low level. Some of these devices have a short service life (few minutes) and are suitable only for escape (self-rescue) from an irrespirable atmosphere. The chief limitations of this type of apparatus are weight and bulkiness, limited service life, and the training required for its maintenance and safe use. The weight of these units vary from 13-40 pounds. In choosing apparatus for a particular job, consideration should be given to the effect of the location of the bulky parts and the sire and weight of the device on the wearer's ability to perform the job efficiently and safely. 7.2,2 Hose Masks. The hose mask with blower is approved for respiratory protection in any atmosphere regardless of the type or consideration of contaminant, provided that enough respirable air is supplied to the wearer. The respirable air supply is not limited to the quantity the individual can carry, and the devices are light weight ar.d simple. The wearer is restricted in movement by the hose or air-line and must return to a respirable atmosphere by retracing his route of entry. The hose or air-line is subject to being severed or pinched off. Hose masks are furnished in two types - one with a blower, the other without. If the blower fails, the unit still provides protection, although a negative pressure exists in the facepiece during inhalation. Use is permissible in atmospheres immediately dangerous to life or health. The hose mask without blower is limited to use in atmospheres from which the wearer can escape unharmed without aid of the respirator. Both types have limitations as to the length and type of hose: the manufacturer's literature should be consulted. 7.2.3 Air-Line Respirators (Continuous Flow, Demand and Pressure-Demand Types) The demand type produces a negative pressure in the facepiece on inhalation whereas continuous flow and pressure-demand types maintain a positive pressure in the facepiece at all times and are less apt to permit inward leakage of contaminants. Air-line respirators are not approved for use in immediately dangerous atmospheres because no protection is provided if the air supply fails. However, pressure-demand or continuous-flow airline respirators with full facepiece provide the wearer with a degree of respiratory protection equal to that afforded by a positive pressure selfcontained breathing apparatus as long as an adequate flow of respirable air is maintained. The airline hose shall be protected from damage, including cutting, kinking, crushing or burning. Hose couplings shall be protected against disconnection. Trailing airline hoses shall be arranged to minimize tripping and to permit ready escape. Airline couplings shall be ftTO nnnoe closing Alcoa's approach, and is not intended lo be a recommendation for any recipient other than Alcoa. No warranties, guarantees or repre sentations, express or implied are made as to the u tility or effectiveness o f the methods, processes, products or procedures described or recommended herein. 0 Engineering Standard ALCOA Materials and Standards Section Pittsburgh RESPIRATORY PROTECTION 18.1.1 PAGE 7 1973-10 incompatible with outlets for other gas systems to prevent inadvertent servicing of airline respirators with nonrespirable gases or oxygen. Continuous-flow airline respirators are designed for maximum comfort with a minimum airflow that will adequately protect the wearer in a non-hazardous atmosphere. However, they are capable of providing adequate airflow to protect the wearer in a hazardous atmosphere. This adequate airflow is obtained when the airflow control valve is fully operf. The recommended minimum airflows for use of airline respirators in hazardous atmospheres are five cubic feet per minute to tightfitting facepieces and seven cubic feet per minute to loose-fitting hoods or helmets. Supplied-air suits protect against atmospheres that affect the skin or mucous membranes or that may be absorbed through the unbroken skin. These suits are limited in use to atmospheres not immediately dangerous to life or health except under the conditions specified in Table 1. Persons wearing supplied-air suits shall follow the manufacturer's instructions concerning minimum airflow. The wearer shall be properly trained in the use of tne airline respirator and shall be well-informed of the hazard.' A standard operating procedure shall be prepared for each situation for which airline respirators are employed in atmospheres immediately hazardous to life or health, and airline respirator users shall be thoroughly familiar with this procedure. 7.2.4 Combination Self-Contained and Air-Line Respirators-!- The equipping of an airline respirator with a small cylinder of compressed air to provide an emergency air supply qualifies the respirator for use in immediately dangerous atmospheres. See Table 1. 7.3 Air-Purifvinq Respirators. Air purifying respirators are designed for use in atmospheres that are not immediately hazardous to life or health, but where long term exposure to low and moderate concentrations of air contaminants may cause bodily harm. These respirators should never be used in atmospheres deficient in oxygen (less than 19.5%). The maximum contaminant concentration against which an air purifying respirator will protect is determined by the designed efficiency and capacity of the cartridge or filter. For gases and vapors and for particles, the maximum concentration for which the air purifying unit is designed is specified on the label. Respirators will not provide the maximum design protection specified unless the facepiece is carefully fitted to the wearer's face to prevent inward leakage. The time period over which protection is provided is dependent on cartridge or filter type, concentration of contaminant, and the wearer's respiratory rate. The proper type of cartridge or filter shall be selected for the particular atmosphere and conditions and shall have Bureau of Mines approval. Cartridge respirators present minimal interference with the wearer's movements. The wearer is not confined to a specific area determined by the length of hose supplying respirable air, and there are no hoses to drag or trip over. Cartridges are easy to change, primarily screw-in type on most models or easily replaced filter pads on others. The same facepiece can be used with different cartridges for protection against a number of contaminants, both gaseous and particulate (including both), simply by using the correct cartridge(s). 7.3.1 Gas and Vapor Respirators. Chemical cartridge respirators provide respiratory protection against certain gases and vapors in concentrations not in excess of 0.1% (1000 ppm) by volume. No protection is provided against particulate contaminants, unless specified on the cartridge label. With chemical cartridge respirators the amount of absorbent or fill is relatively small and has no warning device when exhausted. The wearer must recognize the odor of the contaminant and replace the cartridge. 7.3.1.1. The following general rules apply to the use of chemical cartridge respirators: 1. They should not be used for exposure to harmful gaseous contaminants which cannot clearly be detected by odor. 2. They should not be used against gases or vapors in concentrations which are highly irritating to the eyes. 3. They should not be used against gases and vapors which are extremely toxic in very low concentrations. 4. They cannot be used for protection against gases that are not effectively removed by the absorbant in the cartridge. This standard is Ihc properly o f Aluminum Company o f America and must be returned on request. It shall not be reproduced or copied, in whole or in part, or used on behalf o f others than Aluminum Company o f America or its subsidiaries, w ithout permission. I his engineering standard is provided solely for the purpose o f dis- ATC 00087 0 Engineering Standard ALCOA Materials and Standards Section Pittsburgh RESPIRATORY PROTECTION 18.1.1 PAGE 8 1973-10 5. Cotton facelets should not be used with this type respirator because of leaks of the gaseous contaminant around the facepiece. 7.3.2 Particulate Respirators. Mechanical fiIter respirators provide respiratory protection against particulate matter such as non-volatile dusts, mists and metal fumes, but offer no protection against gases and vapors. Selection of the appropriate respirator is based on the type, toxicity and particle size of the particulates. These respirators shall not be used for shot and sand blasting operations. For these operations abrasive-blasting respirators shall be used. With these filters, increased resistance to breathing indicates a plugging of the filter and the time to replace the filtering unit. Note: A single use filter respirator has been given both U. S. Bureau of Mines and NIOSH approval under the new schedule for respiratory protection against pneumocon iosis and fibrosis producing dusts including but not limited to aluminum, asbestos, coal, flour, iron ore or free silica. 7.4 Combinations of Gas and Vapor and Particulate Respirators. Combinations of chemical cartridge and mechanical filter respirators provide protection where exposure is both gaseous and particulate. Respirators with independently replaceable mechanical filters are preferred for this type because the particulate filter normally plugs before the chemical cartridge is exhausted. One combination mechanical-chemical filter respirator employs a back mounted filter element and is especially suited for spray painting and welding operations where the air contaminant is concentrated in front of the worker. 7.5 Gas Masks. The use of gas masks with air purifying canisters as respiratory protective devices should be discontinued as soon as the current supply of canisters is exhausted. Khan gas masks are used in an emergency, the atmosphere in which they are used may unknowingly be deficient in oxygen or contain higher concentrations of the contaminant than specified for the airpurifying canister (nominally a maximum of 2; bv volume). Also the service life of a canister depends upon a number of factors, not only the duration of usage and the concentration of the contaminant, but also the breathing rate of the wearer and the temperature and humidity of the atmosphere. Since these exposure conditions are subject to wide variations, it is most difficult to estimate the safe service life of a gas mask canister. Furthermore, there are a number of types of canisters available, and each is intended to be used for protection against specific contaminants. In emergency situations it is too easy to choose a mask with an improper canister. An atmosphere-supplying respirator is the recommended replacement for a gas mask. 8. RESPIRABLE AIR AND OXYGEN 8.1 Specifications for Respirable Air and Oxygen.' Compressed air, compressed oxygen, liquid air, and liquid oxygen used for respiration shall be of high purity. Oxygen shall meet the requirements of the United States Pharmacopoeia for medical or breathing oxygen. Breathing air shall meet at least the requirements of the specifi cation for Grade D breathing air as described in Compressed Gas Association Commodity Specification G-7.1-1966. This currently requires that the carbon monoxide level not exceed 20 ppm, the carbon dioxide content not exceed 1000 ppm and condensed hydrocarbons not exceed 5 mg/m^ and there be no pronounced odor. 8.2 Compressed Air. Breathing air may be supplied to respirators from cylinders or air compressors. The compressor for supplying air shall be equipped with necessary safety and standby devices. A breathing-air type compressor shall be used. An air-storage receiver shall also be provided to furnish the wearer with an adequate supply of escape air if the compressor fails to operate. A compressor shutoff alarm and necessary aerosol and vapor and gas filters shall also be incorporated into the system. If an oil-lubricated compressor is used, it shall have a high-temperature or carbon monoxide alarm, or both. If only a hightemperature alarm is used, the air from the compressor shall be frequently tested for carbon monoxide to insure that it meets the specifications for respirable air. The cylinder containing the air supply for an airline respirator shall be tested for oxygen concentration and carbon monoxide content and shall be respirable. The air supply in the cylinder shall be adequate for completion of the work and escape. 8.3 Compressed Oxygen. Compressed oxygen shall not be used in supplied-air respirators or in open-circuit self-contained breathing apparatus that have previously used ATC 00088 closing Alcoa's approach, and is not intended to be a recommendation for any recipient other than Alcoa. No warranties, guarantees or repre scntalions, express or implied are made as to the u tility or effectiveness o f the methods, processes, products or procedures described or recommended herein. 0 Engineering Standard ALCOA Materials and Standards Section Pittsburgh RESPIRATORY PROTECTION 18.1.1 PAGE 9 1973-10 compressed air. Compressed air might contain low concentrations of oil. When high-pressure oxygen passes through an oilor grease-coated orifice, an explosion or fire may occur. 9. TRAINING AND EDUCATION IN PROPER USE OF RESPIRATORY PROTECTION DEVICES 9.1 Training and Education. For safe use of any respirator, it is essential that the user be properly instructed in its selection, use, and maintenance. Both supervisors and workers shall be so instructed by competent persons. Minimum training shall include the following: 1. Instruction in the nature of the hazard, whether acute, chronic, or both, and an honest appraisal of what may happen if the respirator is not used. 2. Explanation of why more positive control is not immediately feasible. This shall include recognition that every reasonable effort is being made to reduce or eliminate the need for respirators. 3. A discussion of why this is the proper type of respirator for the particular purpose. 4. A discussion of the capabilities and limitations of the respirator. 3. Instruction and training in actual use of the respirator (especially a respirator for emergency use), and close and frequent supervision to assure that it continues to be properly used. 6. Classroom and field training to recognize and- cope with emergency situations. 7. Other special training as needed for special use. 9.2 Instructions for Use. Every respirator wearer shall receive fitting instructions including demonstrations and practice in how the respirator should be worn, how to adjust it, and how to determine if it fits properly It should be noted that an improper fit can be caused by a growth of beard, sideburns, a skull cap, temple pieces on glasses and absence of one or both dentures. Persons using air-line respirators in atmospheres immediately hazardous to life ~ r hea.lt.-. shall oe eoulrted safety ..amasses anc safety imes for lifting or removinc persons from hazardous atmospheres. A standby man or men with suitable selfcontained breathing apparatus shall be at the nearest fresh air base for emergency rescue s' Facepiece Fit Tests. To assure proper protection, the facepiece fit shall be checked by the wearer each time he puts on the respirator. This may be done by following the manufacturer's facepiece fitting instructions. Two simple field tests' are described: 1. Positive Pressure Test Close the exhalation valve and exhale gently into the facepiece. The face fit is considered satisfactory if a slight positive pressure can be built up inside the facepiece without any evidence of outward leakage of air at the seal. For most respirators, this method of leak testing requires that the wearer first remove the exhalation valve cover and then carefully replace it after the test. 2. Negative Pressure Test Close off the inlet opening of the cartridge(s) by covering with the palm cf the hand(s) or by replacing the seal(s), inhale gently so that the facepiece collapses slightly, and hold the breath for ten seconds. If the facepiece remains in its slightly collapsed condition and no inward leakage of air is detected, the tightness of the respirator is probably satisfactory. To check the fit of a respirator equipped with a high-efficiency particulate filter, an irritant smoke tube, filled with stannic chloride-impregnated pumice, produces a very irritating smoke when air is blown through it. The smoke is directed at the facepiece seal and leakage is indicated by irritation of the nose and throat. 10. MAINTENANCE AND CARE OF RESPIRATORS 10.1 Program. A program for maintenance and care of respirators shall be adjusted to the type of plant, working conditions and hazards involved. Equipment shall be properly maintained to retain its original effectiveness. The Departmental Coordinator shall have the responsibility for implemen ting the following basic services: 1. Inspection for defects 2. Cleaning and sanitizing 3. Repair 4. Storage 'I his staiiduiil is ilic properly o f A liim inuin Company o f America and must be relumed on request. It shall not he reproduced or copied, in whole or in part, or used on behalf o f others than Aluminum Company o f America or its subsidiaries, w ithout permission. 1 his engineering standard is provided solely for the purpose o f dis- ATC 00089 Q Engineering Standard ALCOA Materials and Standards Section-Pittsburgh RESPIRATORY PROTECTION 18.1.1 PAGE 10 1973-10 10.2 Respirator Inspection. The respirator shall be inspected routinely before and after each use by the employee to whom it has been assigned. A respirator that is not routinely used, but is kept ready for emergency use, shall be inspected after each use and at least monthly to assure that it is in satisfactory working condition. Self-contained breathing apparatus shall be inspected monthly. Air and oxygen cylinders shall be fully charged according to the manufacturer's instructions. It shall be determined that the regulator and warning devices function properly. Respirator inspection shall include a check of the tightness of connections and the condition of the facepiece, headbands, valves, connecting tube and cartridges. Rubber or elastomer parts shall be inspected for pliability and signs of deterioration. The Departmental Coordinator shall keep a record of inspection dates and findings for respirators maintained for emergency use. 10.3 Cleaning and Sanitizing. Routinely used respirators shall be cleaned and sanitized as frequently as necessary to insure that proper protection is provided for the wearer. Each worker should be briefed on the cleaning procedures. Respirators maintained for emergency use shall be cleaned and sanitized after each use. 10.3.1 Method of Cleaning and Sanitizing, The following description is the recommended method of cleaning and sanitizing respirators: 1. Disassemble respirator. 2. Clean and disinfect facepiece and breathing tube in warm (120 F) cleanerdisinfectant solution. This may be prepared from quaternary-ammonia, detergent and alkaline-salt compounds that are available from respirator manufacturers and other sources. Rinse thoroughly in warm water since wearer may be allergic to quaternary-ammonia compounds. or Clean facepiece anti .breathing tube in a warm (120 F) liquid detergent solution, rinse in warm water, then immerse for 2 minutes in one of the following: a. Hypochlorite solution (50 ppm chlorine) prepared by diluting concentrated hypochlorite solution (5 percent chlorine) with water. b. Aqueous iodine solution (50 ppm iodine) prepared by dissolving soluble iodine compound in water. Note: 50 ppm is equivalent to .005 percent. Chlorine and iodine solutions stronger than 50 ppm may damage rubber parts. 3. Air dry in a clean place. 10.3.2 Responsibility. The Departmental Coordinator shall be responsible for assigning the duty of cleaning and sanitizing of respirators. Routinely used respirators, because of their frequency of use, can be maintained by the employee himself after he has been instructed in the proper method. Respirators for emergency use shall be cleaned and sanitized after each use. Although this service is normally provided by the Medical Department, it may be assigned elsewhere. 10.4 Repair and Storage. Replacement or repairs shall be done only by experienced persons with parts designed for the respirator. No attempt shall be made to replace components or to make adjustments or repairs beyond the manufacturer's recommendations. Reducing or admission valves or regulators shall be returned to the manufacturer or to a trained technician for adjustment or repair. 10.4.1. After inspection, cleaning and necessary repairs, respirators shall be stored to protect against dust, sunlight, heat, extreme cold, excessive moisture or damaging chemicals. Respirators placed at stations and work areas for emergency use should be quickly accessible at all times and should be stored in compartments built for the purpose. The compartments should be clearly marked. Routinely used respirators, such as dust respirators, may be placed in plastic bags. Respirators should not be stored in such places as lockers or tool boxes unless they are in carrying cases or cartons. Respirators should be packed or stored so that the facepiece and exhalation valve will rest in a normal position so as to insure the integrity of the valve and prevent impairment of function because of distortion of the elastomer facepiece. 00090 during Alcoa's approach, and is nol intended to be a recommendation lor any recipient other than Alcoa. No warranties, guarantees or representations, express or implied are made as to the u tility or effectiveness o f the methods, processes, products or procedures described or recommended herein. Engineering Standard ALCOA Materials and Standards Section Pittsburgh RESPIRATORY PROTECTION 11. BIBLIOGRAPHY 1. Occupational Safety and Health Act (OSHA) CRT 29, Section 1910.134. Federal Register, Oct. 18, 1972. 2. American National Standard (ANSI) Practices for Respiratory Protection, Z88.2, 1969. 3. Respiratory Protective Devices Manual, 1963. American Industrial Hygiene Association (AIHA) and American Conference of Governmental Industrial Hygienists (ACGIH). 4. Basic Elements of Respiratory Protection. Mine Safety Appliances Company, 1972. 5. Fundamentals of Industrial Hygiene. J. B. Olishfslci and F. E. McElray National Safety Council, 1971. 6. Industrial Hygiene and Toxicology. Frank A. Patty, editor. Vol. 1, 1958. 7. Guidelines for Respiratory Protection Program. American Optical Corporation; National Safety Council articles, April-December 1971. 8. Bureau of Mines Information Circular IC 8559. Respirators Approved by the Bureau of Mines as of May 24, 1973. A revision of Information Circular 8436 U. S. Department of Interior. 18.1.1 PAGE 11 1973-10 I his bl:ind;itri ib Die p m |K ily o f Aliim im im Coinpuny o f America and must he returned on request. It shall nol be reproduced or copied, in whole or in part, or used on behalf o f others than Aluminum Company o f America or its subsidiaries, w ithout permission. This engineering standard is provided solely for the purpose o f dis- ATC 00091