Document YrJvJzZ5J1Vw9xNwJRa4mB01V

Villa Polymers Inc. ASubudiatyof Vitto Chemical Company Highway 25 PollOffice Box 91 Abardaon, Mwiiwippi 39730 Phona (601) 369-8111 * ABERDEEN CHEMICAL PLANT SAFETY & HEALTH MANUAL ABERDEEN SUBJECT: Respiratory Protection Program EFFECTIVE DATE: June 10, 1986 PREPARED BY APPROVED BY Safety Supervisor Safety Director VKIA APPROVED BY Manager REFERENCES: CRF 1910.134 OSHA Industrial Hvslene Manual - Chapter V, Dated 12/20/84 I. PURPOSE The purpose of this program Is to ensure that personnel are provided with and correctly use respiratory equipment to protect themselves against respiratory hazards to which they may be exposed. II. SELECTION AND APPROVAL Personnel will be provided with respirators that are appropriate for the hazards to which they may be exposed, and according to American National Standards Institute, Practices for Respiratory Protection, Z 88.2-1980. In addition, the devices selected must the Intended use by the appropriate authority (MESA NIOSH, Bureau of Mines, and/or as prescribed by regulation). A list of respirators approved for plant use appears In Table I (attached) Employee selections of respirators are to be governed by the follow ing: A. Scott Air Paks or Sling Paks must be used when: 1. Working In VCM concentrations above 1000 ppm or unknown. 2. Working in a plant emergency that could Involve vinyl chloride monomer (vapor or fires), chlorine, and other toxic chemicals in potentially high concentrations. B. Air-line respirators may be used: 1. When working in VCM concentrations up to 1000 ppm and as otherwise specified In the Engineering Work Practice Control Plan. 6/10/86 (Replaces 3/09/84) h Section 1.530 Page 1 VAB.0001Q26116 Aberdeen Chemical Plant Safety & Health Manual Aberdeen MS l 2. When working In potentially toxic concentrations of gases other than VCM that are not Immediately hazardous to life or health; e.g: Methanol. 3. As a substitute for 3M Alrhats when they are not available. C. 3M Alrhats are to be used: 1. When handling lead raw materials, Including: a. Charging compound line blenders. b. Performing work In the Color Weigh Room. 2. When charging Dry Blend master batches. 3. When handling asbestos. D. Bullard System 999 Supplied Air Respirators are to be used during PVC dust collector entry work. E. Dust masks are allowed only for non-hazardous situations of convenience; e.g: cold air, overprotection against minor dusting, etc. III. STORAGE AND CLEANING A Routine respirator cleaning is to be done by a Building Atten dant or Compound employees who have 3M Alrhats permanently assigned to them. Under this program, the job responsibilities of the Building Attendant are: 1. Dally retrieval of used respirators from the respirator collection points, which are: a. Compound Supervisor's office area, b Maintenance Shop c. North of Old Vinyl Control Room. d. Northwest comer of the New Reactor Area. e. South of VCM Tank Farm unloading racks. f. 1st Floor, V-ll Dryer Building. 2. Disassembly, cleaning, and disinfecting of all used respirators. 3. Routine Inspection of respirators for obvious defects and replacement of damaged components per instructions by the Safety Inspector. 4. Placing clean respirators inside plastic bags for re-issue. K 6/10/86 (Replaces 3/09/84) *m Section 1.530 Page 2 VAB.0001Q26117 mm r Aberdeen Chemical Plant Safety & Health Manual Aberdeen, MS 5. Distribution of dean, packaged respirators to the dis tribution points, in the types and amounts specified by the Safety Inspector: a. Compound Supervisor's office area. b. Maintenance Shop. c. North of the Old Vinyl Control Room. d. Northwest corner of the New Reactor Area. e. South of VCM Tank Farm unloading racks. f. 1st Floor, V-ll Dryer Building. 6. Maintaining the respirator cleaning room in a clean, orderly condition. 7. Monthly inspection, maintenance, and cleaning of 3M Alrhats. B. User Care of Respirators The normal use cycle for all fresh-air-type respirators is one shift. At the end of the shift of use, these respirators will be returned to the designated collection points. During their shift, employees are expected to take care of their respirators and to prevent unnecessary contamination of facepieces and air hoses with foreign materials, including oils and greases. 3M Alrhats are assigned for use on an individual basis. Each person assigned an Alrhat must perform dally airflow checks and limited maintenance and cleaning. Including filter changes as needed. They must also place their Alrhat inside their assigned Airhat storage cabinet when it is not in actual use and at the end of the work period. Each Airhat must also be turned in monthly for thorough Inspection, maintenance, and cleaning by the Building Attendant. IV. WEARING AND FITTING Employees must use approved respiratory protection when there is potential for overexposure to respiratory hazards. When used, the devices must be worn as instructed and approved. Employees must check facepiece fit each time they don a respirator. The respirator is not to be used unless a good seal is obtained. In addition: A. Plant employees will not be permitted any facial or scalp hair in the respirator seal area. Facial hair outside the respirator seal area is allowed. B. Any facial hair that interferes with respirator valve operation must be trimmed. 6/10/86 (Replaces 3/09/84) Section 1.530 Page 3 VAB.0001026^18 Aberdeen Chemical Plant Safety & Health Manual Aberdeen, MS C. Plant employees who must wear glasses to be able to see when using a respirator must be fitted with respirator Insert glass es. The above three rules also apply to all persons who are not plant employees and who may be required to wear respirators while working In the plant or who are working on jobs that require an entry permit. V. INSPECTION A. Users of respirators must inspect for cleanliness and obvious defects before each use. 3M Airhat users must also verify adequate airflow. B. - -------------------------------- Scott Air Paks and Sling Paks must be checked after each use by a member of the Safety Department. The following items must be verified before any such respirator may be placed back Into service: 1. Cylinder pressure. 2. Regulator valve positions. 3. Cleanliness of respirator and case. 4. Condition of breathing tube, facepiece, and straps. 5. Cylinder condition. 6. Regulator function. 7. Warning alarm function. C. Safety Inspector The Safety Inspector will conduct documented, monthly in spections of: 1. All Scott Air Paks and Sling Paks. 2. Air-line respirators. 3. Bullard System 999 Supplied Air Respirators. The inspection will be for cleanliness, operation and repair needs, including the tightness and condition of all components. 6/10/86 (Replaces 3/09/84) Section 1.530 Page 4 VAB.000.1026119 Aberdeen Chemical Plant Safety & Health Manual Aberdeen, MS VI. BREATHING AIR QUALITY A. Breathing air supplied from cylinders or breathing air compres sors must be grade "D" (or better) per "Compressed Gas Asso ciation Commodity Specification G-7.1,1973," as follows: Oxygen content Hydrocarbons (condensed) Carbon monoxide Carbon dioxide B. Pure oxygen will not be used 19-23% by volume 5 mg. per cubic meter max. 20 ppm, max. 1,000 ppm, max. breathing air. a C. Scott Air Pak and Sling Pak bottles may be charged only by or under the direction of the Safety Department. 1. A bag sample from dach lot of breathing air supplied In cylinders will be taken by the Safety Inspector and analyzed for oxygen content by the Lab. 2. A badge sample of breathing air from the plant breathing air compressors will be taken each week by the Safety Supervisor and analyzed for VCM content by the Lab. E. Breathing Air Compressors The plant breathing air system will be maintained such that the following criteria are met: 1. The compressors used will be breathing air types. 2. The inlet air charcoal filter will be changed out when air sampling results indicate the presence of VCM in excess of 0.4 ppm, VCM. 3. The alarm which indicates compressor failure will be maintained functional. 4. All alr-llne couplings and connections will be kept incom patible with couplings and connections for all other piping. The compressors will be checked daily by the Utility Technicians for proper operation. Any malfunction that Is found should be handled as follows: 1. Isolate the problem. 2. Take corrective action. Including contact of others, turning in of work orders, or other actions as appropriate. 6/10/86 (Replaces 3/09/84) Section 1.530 Page 5 VAB.000.1026120 Aberdeen Chemical Plant Safety A Health Manual Aberdeen MS VII. TRAINING All employees whose job duties require the use of respirators will be instructed in the selection, use, and care of respiratory equip ment. The Safety Department will conduct such training annually for all employees and during each new employee orientation. VIII. PROGRAM INSPECTION AND EVALUATION Employees at all levels must continuously observe and evaluate the respirator program as it applies to their area of plant responsibil ity. All discrepancies must be promptly corrected and program deficiencies reported to the Safety Department, which is charged with the administration of the entire program. IX. MEDICAL EXAMINATION Employees whose work requires them to use respirators must first be medically certified by a licensed physician. re-certification will be necessary thereafter. A periodic The frequency of re-certification will be determined by the Vista Chemical Company Medical Director. h' b 6/10/86 (Replaces 3/09/84) TT Section 1.530 Page 6 VAB.0001026121 TABLE I APPROVED RESPIRATORY EQUIPMENT 1. Scott Presur-Pak Ila Part No. 9001401 Referred to as "Scott Air Pak" A pressure-demand, self-contained breathing apparatus. Used where self-contained air supply is manda tory. In VCM environments, it Is to be used In concentrations above 1,000 ppm or unknown. 2. Scott Presur-Pak 2.2 Same as Scott Presur-Pak II except unit is pressure-demand only. 3. Scott Sling Pak Ila A lightweight, 15-minute duration version of Scott Presur-Pak Ila. 4. Mine Safety Appliance Co. A constant flow, supplled-air Constant Flow Airline Respirator respirator. Used in VCM atmospheres Part No. 460865 of up to 1,000 ppm VCM. Referred to as "Air Line Respirator" 5. Scott Zephyralr Hoseline A constant flow, supplled-air respirator. Used in VCM atmospheres of up to 1,000 ppm VCM. 6. Bullard System 999 Supplied-Air Respirator A constant flow, supplled-air hood-type respirator. For during dust collector entry. use 7. 3M Alrhat Part No. W-316 A powered, air-purifying device using a high efficiency composite filter. For use during work involv ing lead dusts, asbestos, and all blender charging. 8. Mine Safety Appliance Co. Dustfoe 66 Respirator Part No. 46183 (Complete) No. 457486 & 457485 (Filters) An air-purifying device using parti culate filters. For non-hazardous situations of convienence; e.g: cold air, elective overprotection against minor dusting, etc. 6/10/86 (Replaces 3/09/84) Section 1.530 Page 7