Document kDQ0rQRdb9mRV80L6kjDg9rQq

BLOCK 55 RESPIRATORY PROTECTION GUIDE page 2 Neither chemical respirators nor supplied air equipment provides any protection from skin irritation as would he possible in high concen trations of ammonia* A full gas suit should he worn to protect against skin Irritation. AVAILABLE RESPIRATORY PROTECTION EQUIPMENT: I. Ammonia escape respirator (disposable) II. OVAG escape respirator III. Full face gas mask IV. ELSA, Emergency Life Support Apparatus V.Scott Air Pak VI. Supplied breathing air (fixed and portable) GJR revised: 11-15-84 00 073875 CONFIDENTIAL ELOCK 55 RESPIRATORY PROTECTION CHIDE SCOPE: To establish a program for the proper use of respiratory equipment in the DOKANOL/EthanolamineS Plant. RESPONSIBILITY: The plant superintendent vill assign someone to monitor compliance with this program. It is each individual's responsibility to properly maintain and use personal respiratory protection equipment. TRAINING: Shift supervisors will train all personnel under their supervision and the safety supervisor will train all new personnel and all craftsmen. At least one plant technical person will assist each supervisor in this training. Training will include: 1. Respirator Limitations 2. Proper Fit and Use (A proper fit must be demonstrated in testing.) 3. Proper Cleaning and Maintenance 4. Inspection Procedures and Record Keeping 5. Discussion of consequences of over-exposure 6. Wearing respirator for minimum of ten minutes, and 7. Location of gas masks/supplied air equipment. SURVEILLANCE/EVALUATION: An annual survey of exposure to personnel is performed to document levels on exposure in the various plant areas. This information is reviewed with the Medical Department, Industrial Hygiene Department, and with all plant personnel annually. All plant personnel are given a physical before reporting to work and on an annual basis thereafter. This physical includes determination of ability to wear a respirator. Performance of this respiratory protection guide will be reviewed annually with the Safety Department, and the Industrial Hygiene Department. GENERAL: There are no routine jobs in Block 55 which require the wearing of a respirator or supplied air equipment to prevent exposure to a chemical hazard. Some jobs will however require the wearing of respiratory equipment as a precautionary measure only. Chemical respirators can remove only limited quantities of the chemicals specified on the canister. THESE RESPIRATORS DO NOT SUPPLY OXYGEN AND MUST NOT BE USED IN ATMOSPHERES CONTAINING LESS THAN 192 OXYGEN. Chemical respirators provide only a limited amount of protection time. You must leave the area immediately upon the first signs of break through. If you smell or taste the vapors, or if any sign of nausea, dizziness or distress develops, return to fresh air immediately. DO 073826 CONFIDENTIAL BLOCK 55 RESPIRATOR PROTECTION GUIDE page 3 I- AMMONIA ESCAPE RESPIRATOR (disposable) A. Scott Cat. No. 70-AM Disposable Escape Respirator B. This respirator is designed to be used for ESCAPE ONLY. The ammonia respirator was selected to provide protection from the more immediately incapacitating effects of ammonia vs the organic vapors which could be present in this block. C- This respirator will be carried by every person outside of the control building in Block 55. D. The owner's name and expiration date of the respirator will be marked on the respirator with metal marking ink, tape writer, or engraver. E. Each person must inspect his respirator daily and discard it upon the first sign of damage or unserviceability. F. Cleaning is not required because of personal issue of the respirator and the fact that the respirator is disposable. G. This respirator roust be discarded after being used in an ammonia atmosphere. A portion of the respirator's capacity for ammonia is used up each time the respirator is exposed to ammonia. H. Respirators will be issued by the Lab Assistant Chemist. Owner's name and date of issue will be recorded. I. The typical us'eful lifetime of the respirator is 3 months after removal from the sealed plastic bag. ----- Respirators will be checked in monthly shift safety meetings for expired dates and serviceability. This check will be documented on the Respirator Checklist for each shift. 0 0738P7 CONFIDENTIAL II. OVAG ESCAPE RESPIRATOR A. MSA Respirator, mouth piece type. Part No. 463078 B. This respirator is designed to be used for ESCAPE ONLY. This reusable respirator was selected because it is readily distinguishable from the disposable ammonia escape respirator. C. This respirator must be carried by every person when going to another area inside the division whether to a meeting, to pick up supplies, or to work. D. The issuing and marking of these respirators will be identical to that for the disposable respirators. E. After being used or at the end of three months the respirator cartridge must be replaced. At this time the respirator body must be cleaned and disinfected using the MSA Sanitizer Kit. Follow instructions with the kits which are located in the restrooms in the control building. F. These respirators will also be cheeked in the monthly shift safety meeting. This check will be documented on the Respirator Checklist for each shift. NOTE: A separate type of Ovag respirator has been purchased and is now also being used in the Division. Below are the specifics on this new respirator. A. MSHA NIOSH approval number is TC-23C-111. B. This respirator is designed to be used for ESCAPE ONLY. This respirator is disposable and is also readily distinguishable from the ammonia escape respirator. C. Same as "C" above............ ..... D. Same as "D" above. E. After being used or at the end of 3 months, these respirators win be discarded and a new one issued. F. Same as "F" above. DO 07 C0N^X0f 3s?a Ml BLOCK 55 RESPIRATORY PROTECTION GUIDE page 5 III. FULL FACE CAS MASK A. Scott Full Vision with Scott Chin Style 282-OAAX-L canister. This is the only canister available for the combination of the hazards which are possible in the DOWANOL<S-Ethanolamines plant. B. These full face gas masks with the specified canister will provid limited protection for organic vapors, acid gases (e.g. HC1 and chlorine), ammonia, and light dusts, smokes, and mists. The gas masks will be used in lieu of the dual cartridge respirator to pro vide more protection and to provide protection from both ammonia and organic vapors in one mask. C. These masks may be used for working in any situation where light concentrations of ammonia, alcohol, EO or PO, or any DOWANOLEthanolamines product could be encountered. There are no routine jobs at present which involve over-exposure to any chemical vapor hazard. Jobs where gas masks are required as a precaution will be discussed later. D. Each person assigned to Block 55 will have a personal gas mask issued. This mask will be stored in a plastic box marked with the owner's full name. All these masks will be stored in the control room. Thechnical and office personnel may keep their gas masks in their office. Each facepiece will have a sequential number marked with metal marking ink in the lowest point of the lens (lowest point of left lens for twin lens facepiece). E. The canister on the gas mask must be changed one year after the seal is broken or before the expiration date, whichever is first. The canister must also he changed before storing the mask after each use. Do not remove the canister seal until ready to use the mask. F. Each person is responsible for inspecting his gas mask after each use. Each shift will also inspect gas masks at that shift's monthly safety meeting. Inspection will include; but not be limited to: 1. Canister expiration date, 2. Intergrlty of rubber face piece/straps, 3. Fit check, A. Cleanliness, and 5. Proper operation. Defective gas masks must be repaired or replaced. This check will be documented on the Respirator Checklist for each shift: G. Personal gas masks will be fitted with prescription eye-glasses for those personnel requiring them. Eyeglasses with sidearms will not he worn when wearing the gas mask. H. Gas masks must be cleaned and disinfected using the MSA Sanitizer Kit. Follow instructions with the kit. Kits will be located in restrooms in control building. Kits may be ordered as MSA 34337 Sanitizer Kit from Louisiana Welding Supply. 073829 CONFIDENTIAL BLOCK 55 respiratory protection guide P3ge 6 IV. ELSA, EMERGENCY LIFE SUPPORT APPARATUS A. International Safety Instruments, Inc. ELSA, Emergency Life Support Apparatus, 5 minutes duration - For Escape use only. B. The ELSA unit vill be used to replace the Robert Shaw Air Capsules as a source of 5 minutes of breathing air for escape purposes only. C. ELSA units are located in pairs in areas of possible ammonia exposure. 1. D-218 Structure, Top Deck, 2. D-205, Top Deck, 3. Near C-205 4. North of Ammonia Tank Car Spot on Rack, and 5. South of Ammonia Tank Car Spot on Rack. D. Pressure and condition of each unit is inspected on the weekend saf ty check. Minimum pressure must be maintain in full range of pressure gauge (1800 to 2216 psig). E. OPERATION: 1/ Use only hand pressure to open or close cylinder valve. Use no tools. 2. Lift flap to remove hood 3. Open valve fully 4. Don hood 5. Head for safe areaF. Two spare units are located in the shop. An expended unit must be replaced. G. Expended units should be returned to the Shop so that the Material Controller may have them refilled at Stock. DO 073830 CONFTDFNTTAl BLOCK 55 RESPIRATORY PROTECTION CUIPL page 7 V. SCOTT AIR-FAK A. Scott Air--Pak, 30 minute 1. Scott Air-Pak II, Pressure Demand self-contained breathing apparatus. 2. This Air-Pak provides personnel with maximum respiratory pro tection while performing work in toxic atmospheres regardless of concentration or oxygen deficiency. 3. The regulator is equipped with a low pressure alarm to warn the user in sufficient time for escape from the contaminated area. 4. This Air-Pak is rated at 30 minutes under moderate working conditions. Where work is more strenuous, the duration may be shorter, possibly as short as 15 minutes. 5. Air-Pak cylinder pressure must be checked on a weekly basis and maintained above 1800 psig. Air-Paks must be checked in use monthly and the low-air alarm tested monthly. 6. NORMAL OPERATION: a. Check cylinder gauge for "FULL" indication b. Dor. the Air-Pak by backing up to the cabinet, placing your arms through the shoulder straps, 'and connecting the chest buckle. Pull down on the side straps to adjust the harness. c. Connect and adjust the waist belt. d. Check that the control lever is in the "OFF" position. e. Open the cylinder valve l*s turns end don the facepiece, adjusting it properly for a good seal. f. Check the seal by closing off the breathing tube with your hand and inhaling slowly. g. Connect the breathing tube on the regulator at the quick connect coupling when ready to enter the contaminated area; tighten finger tight. h. Place regulator control lever in the "ON" position. i* After use and in a safe area, place control lever in the "OFF" position, uncouple the breathing tube, and close the cylinder valve. Bleed the residual pressure down by moment arily opening the by-pass valve (red knob). Replace cylinder and return Air-Pak to its cabinet. DO 073831 CONFIDENTIAL BLOCK 55 RESPIRATORY PROTECTION' GUIDE page 8 V. SCOTT AIR-PAX (continued) 7. EMERGENCY OPERATION: a. This method should be used only if the regulator malfunctions during use. Operation of the Air-Pak in this tanner is for ESCAPE ONLY. b. Open and adjust the by-pass valve (red knob). C. Depress the locking tab under the regulator shut-off valve (yellow knob) and turn the valve off (full clockwise). d. Red tag and remove the Air-Pak for repair. 8. The face piece must be cleaned and disinfected after each use. This is the responsibility of the person who used the Air-Pak. a. Carefully wash the facepiece using the MSA Sanitizer Kit. b. Rinse the facepiece thoroughly by flushing water through the breathing tube and letting it flow out through the opening onto the lens. c. After rinsing, the facepiece and breathing tube must air dry completely. Be sure all components are thoroughly dry before replacing in cabinet. 9. Five Air-Pak's are located in the Control Room. Five others are located in the field. a. Area I Sump railing__ _ ......... . b. Near F-250 A/B c. Southeast corner Area III dike wall. d. Ammonia tank truck offloading e. Near center of T/C loading rack. .. 10. Annual inspection-of Air-Pak by the vendor is corrdinated by the Safety Department- DO 07383? CONFIDENTIAL BLOCK 55 RESPIRATORY PROTECTION GUIDE page 9 V. SCOTT AIR-PAK (continued) B. SCOTT AIR-PAK, 5 MINUTE I- Scott Ska-Pale Emergency Escape Unit, Pressure Demand selfcontained breathing apparatus. 2. These Air-Paks are designed for ESCAPE ONLY and are used in vessel entry and as supplemental air on air lines. . 3. Pressure and condition of each unit should be checked weekly and before each use. 0O COtyfr 073833 fDr/vr BLOCK 55 RESPIRATORY PROTECTION GUIDE page 10 V, SCOTT AIR-PAK (continued) C. SUPPLIED - AIR SUIT 1. This suit should be used in circumstances vhere a high Concentration of ammonia vapors are present. 2. The Air-Pak must be donned after the suit and connected to the suit's breathing tube. 3. Operational procedures and cleaning requirements are the same as for the 30 minute Air-Pak. DO 073834 CONFIDENTIAL BLOCK 55 RESPIRATORY PROTECTION GUIDE page II VI. SUPPLIED BREATHING AIR A. FIXED SOURCE- CONTROL ROOM 1. The face pieces in the Control Room, are pressure demand type. ' 2. Cylinder pressure will he checked weekly and must he maintained above 1800 psig. 3. A low pressure alarm is set at 400 psig cylinder pressure to provide the user tine to prepare to evacuate when he is out of air. 4. Supplement 5-ruinute Air-Paks are provided on these air lines for ESCAPE ONLY. 5. The Facepiece must be thoroughly cleaned using the MSA Sanitizer Kit after each use. This is the responsibility of the person who used the equipment. 6. This equipment will be tested in use including checking the low pressure alarm on a monthly basis. B. PORTABLE SOURCE - BREATHING AIR CART 1. The cart consists of two breathing air cylinders, regulator, hoses, and three facepieces. 2. A low pressure alarm is included as a part of the regulator. 3. Cylinder pressure and operation of all apparatus will be checked on a monthly basis. 4. The facepiece must be thoroughly cleaned using the MSA Sanitizer Kitt after each use. This is the responsibility of the person who used the equipment. ( DO 073835 CONFIDENTIAL BLOCK 55 RESPIRATORY PROTECT]ON GUIDE page 12 CONSEQUENCES OF OVER EXPOSURE AMMONIA------------------- TLV 25 ppm. Odor threshold 50 ppm. Overexposure consequences: Severe burn to skin and eyes, severe irritation of respiratory system. METHANOL--------- ----- - TLV 200 ppm. Odor threshold 1500+ ppm. Overexposure consequences: Redness and dryness of skin, eye irritation, inhalation may cause nervousness or dizziness. BUTANOL--------------------TLV 50 ppm, Odor threshold 10 ppm. Overexposure con sequences: Irritation to skin and eyes, inhalation ms cause irritation, dizziness, or crying (laehrymator effect). EO-------------------------- TLV 1 ppm (DOW), Odor threshold 100-800 ppm. Over-.. exposure consequences: Frostbite or burn to skin, possible permanent eye damage, inhalation may cause drowsiness and dizziness. Suspected carcinogen. P0-------------------------- - TLV 3 ppm. Odor threshold 35-200 ppm. Overexposure consequences: May cause burns to skin and eyes, irritation to respiratory system. ETHANOLAMINES------- TLV 3 ppm (MEA), Overexposure consequences: May cuase burn to skin or eyes, inhalation may cause irritation, D0WAN0L-----------------TLV 25 ppm (EB), 100 ppm (PM), Overexposure Con sequences: Moderate irritation to skin and eyes, inhalation may cause drowsiness or nausea. DO 073836 CONFIDENTIAL BLOCK 55 RESPIRATORY PROTECTION GUIDE page 13 JOBS WHICH REQUIRE FULLFACE GAS MASKS The following jobs are those in the DOWAKOL-Etbanolamines plant which re quire the wearing of a gas mask. The masks are worn for these jobs only a precautionary measure since exposure monitoring has shown no problems. No list can cover every situation which might arise. The individual and his supervisor must be on the lookout for situations which could involve exposure to a chemical hazard and be sure that the proper protective equipment is provided and used. 1. Pulling ammonia punp - Mask must be worn to prevent exposure to ammonia in the event of a leaking valve or residual ammonia. 2. Breaking into any line/eguipment which last contained ammonia or alcohols. 3. Disconnecting ammonia or butanol tank car - wear mask to prevent exposure to ammonia or butanol remaining in con nections after off-loading is complete. JOBS WHICH REQUIRE SUPPLIED AIR LINE The following jobs are those in the DOKANOL-Ethanolamines plant which re quire the use of a supplied air line. Supplied air is used on these jobs because of the low TLV and in order to prevent any possibility of ex posure. 1. Pulling of any oxide pump. 2. Breaking into any line/equipment which last contained EO or PO. DO 073837 OONFTDFNTTAl