Document pBNmaXJLaBRpq4nzpYwL5ONYk

INDEX RESPIRATORY PROTECTION PROGRAM PURPOSE SCOPE RESPONSIBILITY Plant Superintendent Responsibilities Supervisory Responsibilities Employee Responsibilities Safety Department Responsibilities REQUIREMENTS CONTAMINANT IDENTIFICATION AND MONITORING Respiratory Hazards by Work Area General PVC PVOH Emulsion Acetylenics Catalyst Plant Compounding Plant Laboratories Acetic Acid Loading Utilities SO2 Pilot Plant Maintenance Shops Warehouse, Main Waste Treatment Vinyl Acetate Barge and River Storage Facility Truck Drivers AP00050931 SELECTION OP PROPER RESPIRATORY PROTECTION General Summary of Types of Exposures and Respiratory Protection at Calvert Respiratory Protection Associated with Specific Hazards and Work Areas PVC PVOH Emulsion Acetylenics Catalyst Compounding Laboratories Utilities S02 Pilot Plant Acetic Acid Loading Barge Facility and Vinyl Acetate River Storage Maintenance Warehouse, Main Waste Treatment EMPLOYEE TRAINING RESPIRATORY CLEANING, INSPECTIONS AND MAINTENANCE Scope Responsibility and Frequency Equipment and Supplies Cleaning, Sanitizing and Inspection Procedures a. After each use, for inplant cleaning for lightly soiled respirators (excluding paint and polymer splattered parts), or for monthly inspections of respirators not kept in sealed plastic bags or cases. b. inspections for respirators not requiring cleaning. c. Annual inspection and cleaning. REPAIR OR MAINTENANCE General Qualified People Requirements RECORD KEEPING AP00050932 Appendix I - Typical Forms Appendix II - Training Program Appendix III - Safe Work Practices Appendix IV - Manufacturers' Literature a. 3M Filter Respirator No. 8710 b. Willson 1200 Series c * MSA VCM-SS Canister Mask d. MSA Airline Respirator e. Scott Air PaX AP00050933 I AIR PRODUCTS & CHEMICALS, INC, CHEMICALS GROUP CALVERT PLANT RESPIRATORY PROTECTION PROGRAM PURPOSE This program is intended to provide guidance that will assist respirator users in safeguarding their health and lives through proper selection and use of respirators. SCOPE The scope of this program includes safe practice and requirements for using and maintaining respirators for protection.of the respiratory system from inhalation of particulate matter, noxious gases and vapors, and oxygen deficiency. Exposure control shall be accomplished as far as feasible by accepted engineering methods before considering or instituting the use of respirators. Examples of such methods include enclosure or confinement of an operation, general and local ventilation, and substitution of less toxic materials. RESPONSIBILITY Plant Superintendent Responsibilities 1. Respirators shall be provided when such equipment is necessary to protect the health of the employees, 2. The Plant Superintendent shall provide the respirators which are applicable and suitable for the purpose intended. 3. The Plant Superintendent shall be responsible for the establishment and maintenance of a respiratory protective program. # Supervisory Responsibilities 1. The Production Supervisor is responsible for administering training and inspections. 2. Shift foremen are responsible for conducting inspections to ensure that employees are maintaining routinely used (assigned) respirators properly. These inspections will be conducted at Least monthly. 3. Foremen and supervisors are responsible for insuring that employees are not. exposed to excessive conn-nt i rifionH nf toxic materials. This includes adherence to safe work practices, equipment preparation and maintenance, and wearing of reopi rnfots when toxic materia) concent r a t ions arc1 excessive. AP00050934 2 Employee Responsibilities 1. The employee shall use and maintain the provided respiratory protection in accordance with instructions and training received. 2. The employee shall use a suitable respirator either (a) when he has knowledge of excessive concentrations of toxic materials, or (b} he has reason to believe that concentrations may be excessive. 3. The employee shall guard against damage to the respirator. 4. The employee shall report any malfunction of the respirator to his foreman or supervisor. 5. The employee shall inspect and clean respirators as specified in the cleaning and maintenance section of this program. Safety Department Responsibilities 1. Maintenance and annual inspections-cleaning shall be done by the safety officer on the midnight shift. 2. The safety engineer shall coordinate personnel monitoring and abatement programs on toxic material exposure. REQUIREMENTS Each plant program shall include: 1. Identification and monitoring of airborne contaminants. 2. Selection of proper respiratory protection. 3. Employee training. 4. Maintenance. 5. Inspection. 6. Storage. 7. Record Keeping. AP00050935 3 CONTAMINANT IDENTIFICATION AND MONITORING Respiratory Hazards by Work Area General Subpart Z of OSHA (Part 1910,1000-0.1500) is incorporated by reference on establishing minimum requirements on permissible exposure, practices, etc. The most recent TLV's established by ACGIH are also incorporated by reference. When TLV's of these two references differ, the more stringent TLV applies. PVC The following potential respiratory hazards have been identified in the PVC plant: 1. Vinyl Chloride Monomer (VCM). Area and personnel sampling show concentrations usually below the TLV of 1 ppm. Personnel sampling is done monthly on each shift. 2. Vinyl Acetate (VAc). Area sampling with fixed chromatograph samplers in 1975 show concentrations well below h TLV. Employee exposures are intermittent and are associated with accidental release of materials from closed systems. No process changes have been made that would increase VAc exposure. 3. Propylene. Area sampling with fixed chromatograph samplers in 1975 show concentrations well below the asphyxiation level. Overexposure could result only from an infrequent massive release from a closed system. 4. Dimethylformamide (DMF). Exposure is expected to result only from occasional leaks, etc., from a closed system. 5. PVC Dust, source (area) sampling in July 1974 at suspected high concentration locations showed that railcar loading and the product collector area may have moderately high dust concentrations. Bagging and general plant is lower than TLV. AP00050936 4 PVOH The following potential respiratory hazards have been identified in the PVOH plant: 1. Methyl Alcohol. Area and personnel sampling in 1975 reveal some concentrations above the TLV, without regard to the use of respirators. Personnel sampling on baggers in May and June 1976 showed extremely low concentrations relative to TLV and no process changes have been made that are expected to increase exposure. 2. Methyl Acetate. Area and personnel sampling in 1975 reveal some concentrations above the TLV, without regard to the use of respirators. Personnel monitoring on baggers in May and June 1976 showed extremely low exposure and no changes have been made that are expected to increase methyl acetate levels. 3. Vinyl Acetate. Fixed point chromatograph samplihg in 1975 indicates that vinyl acetate concentration is generally below ^ TLV. No process changes have been made that are expected to increase the exposure. 4. V^n^l JSanoroer ,(VCM). Area sampling performed by the Lab in 1*975 shows that VCM is substantially below the action level. Occasional brief excursions result from nonroutine conditions at the proximate PVC plant coupled with wind from generally southeasterly direction. AP00050937 Emulsion The following materials have been identified as potential respiratory hazards: 1. Vinyl Acetate (VAc). Area sampling by fixed location chromatographs in 1975 show that VAc is typically substantially below the TLV. No process changes have occurred that are expected to increase the exposure. 2. VCM. Area sampling (October and November 1974) and personnel sampling (March and April 1975) establish that VCM is below the action level. No process changes have occurred that are expected to increase the exposure. 3. Ammonia. Will change to a closed system in 1976-77. 4. Formaldehyde. Tending tanks are open; otherwise-a closed system is present. 5. Merbac 35. This material has a low volatility (viscous liquid in petroleum solvent). TLV is not established. Sampling procedure not established. 6. Maleic Anhydride. TLV not established. Analystical procedure received in June 1976; sampling procedure not established. 7. Ethylene in Emulsion Plant- Overexposure is expected to result only from leaks or releases from a closed system. 8. Ethylene in Storage Area. Overexposure is expected to result only from leaks or releases from a closed system. AP00050938 6 Acetylenics The following potential respiratory hazards have been identified: 1. Acetone. Area sampling by the leak patrol using the Century Organic Vapor Analyzer in 1975 showed typical work area concentrations below S TLV. No changes in the process have been made that are expected to increase the exposure. 2. Methyl Ethyl Ketone. Exposure is expected to be comparable to acetone mentioned above/ that is, concentrations are expected to be below the TLV's. 3. Methyl Isobutyl Ketone. Exposure is expected to be comparable to acetone mentioned above, that is, concentrations are expected to be below the TLV's. 4. Isopropyl Ether. 5. Ethylene Glycol. 6. Polypropylene Glycol. 7. Dimethyl Formamide. Area (source) sampling in April and May of 1975 showed concentrations below ^ TLV. No process changes have been made that are expected to increase DMF levels. 8. Renex 20. 9. Potassium Carbonate. 10. Potassium Hydroxide. a. Recent Caustic Building process improvement. Sampling scheduled for midsummer. b. Jackhammering to remove caustic pot--laborers. Concentration high enough to be'irritating. 11. Propargol Alcohol. AP00050939 12. 2-Ethyl Hexanol. 7 13. 2-Ethyl Hexaldehyde. 14. Pluronic P-10S. 15. n-Butyraldehyde. mentioned above, the TLV's. Exposure is expected to be comparable to acetone that is, concentrations are expected to be below 16. Acetylene. Area sampling by the leak patrol using the Century Organic Vapor Analyzer in 1975 showed typical work area concentrations below TLV. No changes in the process have been made that are expected to increase the exposure. 17. Igepal CO-730. 18. VCM from PVC Plant. Area sampling in October and November 1974 showed VCM less than action level. No process changes have been made that are expected to increase exposure. AP00050940 8 Catalyse Plant The following potential respiratory hazards have been identified: 1. Platinum Salt Dust. Area measurements performed on 20 August 1975 indicate that exposure is administratively below the TLV. No process changes have been made that are expected to increase the exposure. 2. Nuisance Dust. Area and personnel sampling in 1975 show that the concentration is less than the TLV. No process changes have been made that are expected to increase nuisance dust exposure. 3. Hydrogen Chloride. Associated with open transfers. Concentration not measured but is occasionally objectionable. AP00050941  9 Compounding Plant The following potential respiratory hazards have been identified: 1. Lead. Area sampling and biological monitoring in July 1976 show that lead dust concentration is below the TLV, in all areas except the blending room and the weigh belt room. No process changes have been made that are expected to increase the concentration. 2. Nuisance Dust. Area sampling in 1975 shows that concentration is less than the TLV. No process changes have been made that are expected to increase the concentration of nuisance dust. 3. Chrominium. Chrominium is generally of concurrent exposure with lead. Sampling is scheduled for late fall. In the interim, respiratory protection is required wherever operating conditions and practices indicate a possible exposure. 4. Cleaning Solvent. Potential exposures are when the blenders are cleaned in changing compound formulations. 5. VCM. Personnel sampling in April and Hay 1975 showed VCM exposure below the action level. No process changes have been made that are expected to increase exposure. AP00050942 10 - Laboratories ---- Possible respiratory hazards are; 1. Platinum in Catalyst Plant Laboratory. Area sampling during October 1975 did not indicate exposure above the TLV. However, the samplinganalysis technique was indirect and strains the extremely low TLV. 2. Lead in PVC Laboratory. An improved local ventilation system is being engineered. 3. Chrominium in PVC Laboratory. An improved local ventilation system is being engineered. 4. Nuisance Dust in Catalyst Plant Laboratory. Area sampling during October 1975 showed exposure below TLV. No changes have been made that are expected to increase nuisance dust concentration. 5. VCM. Personnel sampling in January 1976 in the Main and PVC Labs showed VCM exposures well below the action level. No changes have been made that are expected to increase the concentration. i i AP00050943 11 Acetic Acid Loading The only respiratory hazard is glacial acetic acid. This is primarily present during an accidental spill, and concentration is highly dependent upon atmospheric conditions, especially wind velocity. Utilities 1. Boiler. Only in upset conditions due to loss of fans are respiratory hazards present--incomplete combustion: smoke, fumes, carbon monoxide and lack of oxygen. 2. Sulfur Dioxide. Levels are below the TLV as revealed by area sampling in May 1976. No process changes have been made that are expected to increase the exposure. 3. Chlorine at Cooling Towers. Only during releases from closed system. 4. Flyash at Loading Station. New abatement equipment being installed in midsummer 1976. 5. VCM from PVC. Area monitoring done in October and November 1974 showed VCM less than the action level. No process changes have been made that are expected to increase VCM exposure. AP00050944 12 SO? Pilot Plant Potential respiratory hazards are: 1. Sulfur Dioxide. Area sampling reveals that the level is less than the TLV, No process changes have been made that are expected to increase the exposure. 2. Ammonia. Ammonia's threshold odor is noticeably below the TLV, and the concentration is substantially below the TLV by smell. Pilot Plant is currently shut down. i AP00050945 13 Maintenance Shops 1. Potential respiratory hazards of mechanical, electrical, and instrument workers are cleaning solvents, and burning plastic fumes. Cleaning solvents are diesel fuels used mainly in dip tanks, and burning plastic fumes for which no TLV is established but which tend to be self-regulating because of its offensive odor, and welding fumes. 2. Painters have three potential respiratory hazards associated with their craft: a. Organic Solvent Fumes. Concentrations of organic solvents have been approximated with the Century Organic vapor Analyzer at a maximum in the neighborhood of 1000 ppm (0.1%). b. Silica (from sandblasting). Silica from sandblasting has not been measured but by industrial hygiene practices is accepted to be excessive. c. Paint Mists. 3. VCM. Area monitoring in October and November 1974 showed VCM less than action level in PVC, PVOH and Main Maintenance Shops. No process changes have been made that are expected to increase VCM levels. 4. Refrigeration Shop. Soldering and welding fumes, freon. Recently moved into new shop. Exhausting blower to be installed. 5. Grinding. Highly toxic materials are not knowingly ground at Calvert. 6. Welding Fumes. Highly toxic welding rods are not knowingly used. Area or local ventilation is present in maintenance shops. AP00050946 14 Warehouse, Main 1. Main exposure is from volatile organic vapors escaping from bagged solid plastics and dusts from broken or leaking bags being handled. Weighing is done in front of exhaust fan. a. VCM. January 1975 personnel sampling showed levels below the action level. No changes have been made that are expected to increase exposure. b. Vinyl Acetate. c. Methanol. Area samples in October 1975 showed about ^ TLV or much less. No process changes have been made that are expected to increase concentration. d. Lead Pigment Dusts. Main exposure is from broken or leaking bags. e. Chrominium Pigment Dusts. Mainly associated with broken or leaking bags. f* Carbon Black. Only associated with broken or leaking bags of carbon black pigment. g. Nuisance Dusts. Primarily associated with broken or leaking bags of solids. h. Carbon Monoxide. Area sampling in 1972 with Dragor tubes in railroad cars, trailers, and in warehouse, all with forklifts operating, showed peak exposure less than TLV. No process changes have been made that are expected to increase exposure. i. Methyl Acetate. Personnel sampling was done in June 1976 on PVOH baggers, who are expected to have maximum exposure of warehouse personnel. Levels were substantially below *j TLV. AP00050947 15 Waste Treatment Plant Possible respiratory hazards are as follows: 1. Ammonia. An occasional mild exposure might occur on unloading operations while hooking and unhooking transfer hoses. 2. Slaked Lime. Fine dust during air transfer is charged. A request has been submitted for an engineering improvement. Vinyl Acetate Barge and River Storage Facility 1. Vinyl Acetate. Exposure is expected to be associated only with leaks and unusual occurrences in the outdoor barge and river tank storage facility. Truck Drivers (Bulk PVC) VCM has been identified as a potential respiratory hazard of truck drivers hauling bulk PVC made at the Calvert plant. Personnel monitoring of the driver while: (a) in the Calvert plant, (b) on the road, and (c) unloading at destination, all showed VCM substantially below the action level. No changes have been made that are expected to increase VCM exposure to truck drivers. AP00050948 16 SELECTION OF PROPER RESPIRATORY PROTECTION General __ Where available, NIOSH-approved respirators must be obtained. Prior to the purchase of new respiratory protection, the person placing an order will route the purchase requisition to the safety engineer for approval to ensure that a proper respirator is ordered. Summary of Types of Exposures and Respiratory Protection at Calvert A full range of toxicity is present at Calvert for both dusts and vapors. Dust toxicity ranges from the "nuisance" classification of plastic dusts, to more toxic lead-containing dusts, to materials such as chrominium and platinum dusts where exposure should be very low. Filter respirators are specified for the extent of protection needed, ranging from ordinary efficiency filters to high efficiency. The frequently used filters approved for use at Calvert are as follows: Filter Efficiency Ordinary Medium High Type Respirator Filter Cartridge Cartridge Description 3M 8710 Willson 1200 Series with RIO or Rll Willson 1200 Series with R12 Used With Typical Toxic Materials Plastic dusts, Nuisance dusts, Asbestos Lead Chrominium, Platinum Vapor and gas toxicity likewise range from "low" toxicity of ethylene, and propylene, where asphyxiation due to oxygen displacement is the main hazard, to "medium" toxicity methanol and methyl acetate, to vinyl chloride monomer which should have very low exposures. In general, cartridge or canister respirators are used for low concentration of moderately toxic vapors or gases where sufficient oxygen to support life is present, airline respirators are used for higher concentrations or with materials that require lower exposures such as VCM. Scott Air Paks are used at even higher concentrations and for rescue. APOOC 17 Respiratory Protection Associated With Specific Hazards and Work Areas Respirators specified for possible respiratory hazards in the Calvert plant work areas are as follows: PVC Hazard All VCM Respirator Type Airline Canister Respirator/Cartridges Filters, Canisters ( ) Denotes Suitable But Not Used________ MSA MS A/VCM Comments All concentrations organic 61000 ppm VCM <25 ppm VCM All Self-Contained Scott Air Pak/ Pressure Demand All concentrations organic, VCM PVC Dust Filter (3M No. 8710) Not in Use AP00050950 PVOH Hazard All Respirator Type Airline All but VCM PVOH Dusts Canister Cartridge PVOH Dusts, Organic Vapors Organic Vapors All but VCM PVOH Dusts Cartridge Self-Contained Filter 18 Respirator/Cartridges Filters, Canisters MSA MSA/Type N Willson 1200 Series/ Rll (RIO) Amer. Opt. R-5051/ R-51 Willson 1200 Series/ R21 or R25 Scott Air Pak/ Demand 3M No. 8710 Comments All concentrations organic, $1000 ppm VCM 42% organic Nuisance Dusts 40.1% organic AP00050951 Emulsion Hazard All Respirator Type Airline VCM All but VCM All but VCM Dusts All Canister Canister Self-Contained Filter Self-Contained 19 Respirator/Cartridges Filters, Canisters MSA/Type C MSA/VCM MSA/Type N Scott Air Pak/ Demand (3M No. 8710) Scott Air Pak/ Pressure Demand Comments All concentrations organic, 61000 ppm VCM 625 ppm VCM 62% organic, 63% ammonia Not in Use AP00050952 Acctylcnics Hazards All Respirator Type Self-Contained Caustic Dusts, Product Dusts Caustic Dusts Filter Airline Hood 20 Respirator/Cartridges Filters, Canisters Scott Air Paks/ Demand 3M No. 8710 Comments Clemco AP00050953 Catalyst Hazards Hydrogen Chloride PT Dusts Respirator Type Cartridge Cartridge Nuisance Dusts Filter 21 - Respirator/Cartridges Filters, Canisters Willson 1200 Series/ R25 Willson 1200 series/ R12 3M No. 8710 Comments AP00050954 Compounding Hazards Lead Dusts, Nuisance Dusts Chrominium Dusts ' Nuisance Dusts Organic Vapors Respirator Type Cartridge Cartridge Filter Cartridge 22 Respirator/Cartridges Filters, Canisters Willson 1200 Series/ RIO (Rll, R12) Willson 1200 Series R12 3M No. 8710 Willson 1200 Series/ R21 Comments AP00050955 Laboratories Hazards Platinum Lead Respirator Type Cartridge Cartridge Chrominium Cartridge 23 Respirator/Cartridges Filters, Canisters Willson 1200 Series/ R12 Willson 1200 Series/ RIO (Rll, R12) Willson 1200 Series/ R12 Comments AP00050956 I - 24 - Utilities Hazards Smoke, Fumes, Carbon Monoxide Combined With ' Possible Lack of Oxygen (Indoors) Smoke, Fumes (Outdoors) Respirator Type Self-Contained Cartridge Respirator/Cartridges Filters, Canisters Scott Air Pak/ Demand Willson 1200 Series R25 (R21) Comments Chlorine, S2 Fly ash so2 Canister Filter Cartridge MSA/Type'GML 3M No. 8710 Willson 1200 Series/ R25 I # AP00050957 SO- Pilot Plant Hazards s2 so2 Ammonia Respirator Type Cartridge Canister Cartridge Ammonia Canister 25 Respirator/Cartridges Filters, Canisters Willson 1200 Series/ R25 MSA/Type GML Willson 1200 Series/ R24 MSA/Type N Comments AP00050958 Acetic Acid Loading Hazards Acetic Acid Acetic Acid Respirator Type Cartridge Canister 26 Respirator/Cartridges Filters, Canisters Willson 1200 Series/ R25 or R21 MSA/Type N Comments Barge Facility and Vinyl Acetate River Storage Hazards Vinyl Acetate Respirator Type Self-Contained Respirator/Cartridges Filters, Canisters Scott Air Pak/ Demand Comments AP00050959 Maintenance Hazards Paint Mists, Solvents Paint Mists, Solvents Silica Cleaning Solvent, Burning Plastics Burning Plastics Respirator Type Cartridge Cartridge Airline Hood Cartridge Airline 27 Respirator/Cartridges Filters, Canisters Amer. 0pt./R9lP Willson 1200 Series/ <R14, R21) Comments Willson 1200 Series/ {R21 or R25) MSA Use only when eye irritation is not present Full face mask is needed where fumes can irritate eyes or facial skin AP00050960 warehouse, Main Hazards Lead Dust Chrominium Respirator Type Cartridge Cartridge Carbon Black Nuisance Dusts Filter Filter 28 - Respirator/Cartridges Filters, Canisters Willson 1200 Series/ RIO Willson 1200 Series/ R12 3M No. 8710 3M No. 8710 or Willson 1200 Series/ R10 Comments AP00050961 Waste Treatment Hazards Ammonia Slaked Lime Respirator Type Canister Filter 29 Respirator/Cartridges Filters, Canisters MSA/Type C 3M No. 8710 Comments <3% ammonia AP00050962 30 EMPLOYEE TRAINING For the 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. All new employees are trained by their foremen. Retraining is done at least every two years for those employees who might have occasion to use a respirator. An acceptable basic training program is attached as Appendix I. Training includes the following: 1. Instruction in the nature of the hazards associated with the employee's present work, whether acute, chronic, or both, and an honest appraisal of what may happen if the respirator is not used. A general summary of hazard types in the Calvert complex is also mentioned. Refer to "Contaminant Identification" section for hazards in a particular plant. 2. Explanation of why more positive control is not immediately feasible, including recognition that every reasonable effort is being made to reduce or eliminate the need for respiratory protective devices. 3. A discussion of why this is the proper type of respirator for the particular purpose. / A. A discussion of the respirator's capabilities and limitations. 5. Instruction and training in examination of respirators for defects, and on cleaning respirators. 6. Instruction and training in actual use of the respirator and close and frequent supervision to assure that it continues to be properly used. This includes a demonstration and practice session on how the respirator should be worn, how to adjust it, and how to determine if it fits properly (leak check). It should also be pointed out to employees that certain conditions may prevent a good face seal. Such conditions may be a growth of beard, sideburns, a skull cap that projects under the facepiece, or temple pieces on eye glasses. Also, the absence of one or both dentures can seriously affect the fit of the facepiece. 7. Review of Safe Work Practices on using respirators. B. Classroom and field training to recognize and cope with emergency situations. 9. Special situations, if any. AP00050963 - 31 RESPIRATOR CLEANING, INSPECTIONS AND MAINTENANCE Scope The Calvert plant program for maintenance and care of respirators includes the following basic services: 1. Inspection for defects (including a leak check). 2. Cleaning and disinfecting. 3. Repair. 4. Storage. Equipment shall be properly maintained to retain its original effective ness. This cleaning and maintenance program applies, to every respirator (except disposable) at the Calvert plant. Responsibility and Frequency 1. Inplant (local) cleaning by respirator users or assignees. Every respirator is to be cleaned: a. Whenever soiled. b. After each use (at end of shift or day's work). c. Monthly if not always kept in a sealed plastic bag or other sealed container. 2. Inplant (local) inspection. a. Every respirator shall be inspected after each shift that it is used or carried. b. Every respirator shall be inspected at least monthly regardless of use. 3. Annual inspection by safety department. a. Every respirator is to be inspected and cleaned annually by the safety officer on the midnight shift. 4. Repairs. a. Defective respirators will be repaired only by a qualified person, including replacing straps, valves, etc. Qualified people are those trained in the respirator maintenance program described in a later section. b. Repairs can be made by the safety officer on tho midnight shift. Respirators arc to bo picked up and delivered by the department using or assigned the respirators. AP00050964 32 Equipment and Supplies 1. MSA Cleaner-Sanitizer Catalog Number 34337. Local vendor is Calvert Industrial Supply. 2. Brushes a. Tapered bottle brush. b. Compact utility brush. 3. Toweling. Choose from terry cloth, lint-free cotton or linen, tablecloth, paper towels. 4. Rubber gloves are desirable when many respirators are washed at any one time. 5. Plastic Bags. Any "Baggie" or other plastic bag large enough to contain the cartridge or canister respirator. 6. Plastic or rubber apron for mass respirator cleaning. 7. Lab coat or coveralls for mass respirator cleaning. 8. Two deep sinks and/or pails for washing-rinsing respirators. 9. Tags or paper for respirator I.D. AP00050965 33 - Cleaning, Sanitizing and inspection Procedures A. AEter each use, for inplant periodic cleaning for lightly soiled respirators (excluding paint and polymer splattered parts), or for monthly inspections of respirators not kept in sealed plastic bags or cases. L. Prepare cleaning-sanitizing solution by adding one package (1 oz.) of powdered MSA cleaner-sanitizer to each gallon of warm water (about 120 F) . 2. Leak check the respirators (the same way that tightness of facepiece fit is tested). 3. a. For cartridge and canister respirators, remove all filters, cartridges or canisters and discard if used, b. Remove all parts that are defective by visual inspection and discard these defective parts, including defective rubber (pliability, signs of deterioration), valves not seated properly, unclear lens. 4. Immerse respirator (parts) in the cleaning-sanitizing solution and scrub gently with a soft brush until clean. Pick up valve edges and wash seating surfaces with fingers or brush (alterna tively removing valves). 5. Rinse in plain, warm water (about 120 F). 6. Either air dry or blow dry (compressed air) the cleaned respirator parts. 7. Remove and discard parts that remain uncleaned (generally check with your supervisor). 8. Replace all valves (inhalation, exhalation), all filters, cartridges, canisters, and replacement parts. 9. Check connections for tightness. B. Inspections for Respirators Not Requiring Cleaning 1. Do not leak check, as respirator would then need cleaning. 2. Take respirator out of case, box, or bag. 3. Visually and manually inspect for defective or missing parts, including defective rubber (pliability, signs of deterioration), valves not properly seated, canister expiration date, air tanks full, NIOSH approval on cartridges, unclear lens, warning devices and regulators on Scott Air Paks work, tightness of connections. AP00050966 34 4. Replace respirator in storage container {box, bag, or carrying case)< c. Annual Inspection and Cleaning General. The same steps apply as in section A for lightly soiled respirators except that a complete respirator disassembly and more inspections are done. A respirator is thoroughly visually inspected both before breakdown, during breakdown, and after reassembly. The specific steps are as follows: 1. Prepare cleaning-sanitizing solution by adding one package (1 oz.) of powdered MSA cleaner-sanitizer to each gallon of warm water (about 120 F). 2. Leak check, the respirators (the same way that tightness of facepiece fit is tested). 3. Thoroughly visually inspect each Respirator for defects, including defective rubber (pliability, signs of deterioration), valves not seating properly, missing parts, unclear lens (glass or plastic), air tanks not fully charged, tightness of connections, canister expiration dates. 4. Completely break down the respirator, including removing all headstraps, lens, valves, and valve covers, breathing tubes, filters, cartridges, canisters, etc. Inspect each part. 5. a. Discard filters, cartridges, canisters with seal missing or nearing expiration date, and defective parts. b. Segregate paint splattered, polymer splattered, or rusty parts for special cleaning. 6. Immerse respirator parts in the warm (about 120 F) cleaningsanitizing solution and scrub gently with a soft brush until clean. 7. Rinse in plain warm water (about 120 F). 8. Either air dry or blow dry (compressed air) the cleaned parts. 9. Remove and discard parts that could not be cleaned. 10. Reassemble, using new valves, filters, cartridges, and replacement parts. 11. Visually inspect. 12. a. Place each cartridge or canister respirator in a plastic bag, seal, and label by department and respirator number. b. Place each canister renpirntor (gas mack) and Scott Air Pak in its carrying case when the case is available. AP00050967 35 REPAIR OR MAINTENANCE General Replacement or repairs shall be done only by qualified persons with parts designed for the respirator. No attempt shall be made to replace components or to make adjustments or repairs beyond the manufacturers' recommendations. Reducing or admission valves or regulators shall be returned to the manu facturer for adjustment or repair. Qualified People Requirements Qualified people for repairs are those that meet the following requirements? 1. Have taken the basic course(s) on respirator theory and practice, including examining respirators for defects. 2. Have taken a respirator repair course administered by the safety department that includes: a. Leak testing respirators by fitting to head and checking for fit (and leaks) per instructions for each respirator. b. Visual, manual and flow testing of respirators as necessary to locate defective or missing parts, including defective rubber (pliability, signs of deterioration), valves not properly seated, canister expiration date, air tanks full, NIOSH approval on cartridges, unclear lens, warning devices and regulators work, tightness of connections. c. Disassembly of respirator to basic components (straps, tanks including valves, regulators, carrying harness (Scott Air Pak), facepiece including attached lens, valves, valve covers, canisters, cartridges. d. Cleaning all parts as directed. e. Reassembly of respirator. f. Visual and manual inspection for completeness. AP00050968 36 RECORD KEEPING Every airline or cartridge respirator shall be numbered. issuance, and the person or use assigned should be recorded. The date of A record shall be kept of inspection dates, findings, and cleaning for all respirators. A form for this purpose is attached (Appendix II). Other forms accomplishing the same purpose may be used. A record shall be kept of respirator training. Each employee receiving training shall acknowledge the type of training he received by signing a form similar to that shown as Appendix III, or any written record may be used that accomplishes the same purpose. A record shall be kept of Respirator Repair Training to train qualified people. AP00050969 Jp AIR PUODUCIb it uiiLi-ii , 4,v. A - '/* CHEMICALS GROUP RESnIRATQR INSPECTION FORM 'ISTR'JCTIONS FOR COMPLETING THIS FORM: . .ill in date and overall rating of either 1 or 2. . For each category indicate (by number) the condition found and the servicss performed. For example, under ''cleanliness" a dirty respirator would be indicated as 2-3. RESPIRATOR DESCRIPTION; USE: ISSUED TO: DATE: CONDITIONS FOUND AND SERVICES PERFORMED: 1. SATISFACTORY 2. UNSATISFACTORY 3. CLEANED ' 4 , REPAIRED 5. REPLACED c * REFILLED DATE OF LAST INSPECTION AND RESULTS RESPIRATOR TRAINING Mr. was trained in the below-listed phases of respirator use that are acknowledged: TYPE OF TRAINING INSTRUCTOR DATE SIGNATURE OF INDIVIDUAL Cartridge Respirator familiarization, instruction, and demonstrated use Scott Air Pak familiarization, instruction, and demonstrated use Safe Work Practice reviev/ on cartridge respirator Practice using cartridge respirator (Add others as needed) ,; i I i i ' (EX I BIT II) 1 >: AP00050971 ;e OPERATOR FRESH AIR MASK INSPECTION ___ SHIFT MASK CLEANED AND IN OPERATING CARTRIDGES OPERATOR'S __ AVAILABLE DISINFECTED CONDITION ISSUED INITIALS m COMMENTS SHIFT FOREMAN'S SICNATURE_ DAY SUPERVISOR'S SICNATURF. AREA FOREMAN'S SIGNATURE AP00050972 - ( ' c APPENDIX V ^ ^ ./*. v Tf?/* '-/'>/*- TRAINING AIDS O- /;<* '- ^r` * A. All items in Section B below plus the white filter mask by 3M. r<?>. B. Defect examination of respirators Respirator No. 1. Airline respirator with missing regulator components (diaphragm and regulator cover plate with control knob) (hose is also presently missing) , Respirator No. 2. Cartridge respirator with missing valve. Respirator No. 3. Cartridge respirator with "dirt" on exhalation valve (Scotch tape used to hold a piece of matter on the sealing surface). Comment that the dirt, piece of plastic, etc. can either be wiped off with a finger, etc. or washed off. Respirator No. 4. Airline respirator with a missing strap. C. Practice wearing of Respirators 1. Cartridge Respirator (Use defective respirator No. 2 with the missing valve). 2. CanisterRespirator (In red storage box), 3. Airline full face respirator (MSA) with two 25 foot hoses and the Acme filter and regulator station. 4. Lysol Spray Disinfectant and towels. D. Safe Work Practices 1. On cartridge and canister respirators 2. On airline respirators / AP00050973 -"APPFND'T X' ? SUGGESTED TRAINING FORMAT \. Briefly state why respirators are worn and when each type is worn. 1. Why - they are worn to protect a person from toxic (harmful) materials from entering the lungs. 2. When - usually foreman will tell their men about the particular hazards in their plant and about what respirators to wear. The basic ideas are (hold up a sample of each respirator as you mention it): a. Cartridge respirator - low (0.1* or less) concentrations 'of vapor or gas for the cartridge portion and for high concentrations of dust or other solids for the filter. Must have enough oxygen in the air. b. The 3M dust-type filter (white mask) is good for low toxicity dusts - most of our materials except lead fall into this category. It offers no protection against harmful gases or vapors. Must have enough oxygen in the air for breathing. c. Canister masks (chest type is usually stocked) - offers protection for higher concentrations of toxic materials (usually up to 2%). and for longer times. The all purpose canis ter., which is generally stocked, offers protection against carbon monoxide. Must have enough oxygen in the air for breathing. d. Airline respirators - furnishes complete protection against any atmosphere not immediately dangerous to life (you can take off the respirator and walk or run to safety without being killed or seriously injured). B. Practice on locating respirator defects. All but one are defective respirators as they were taken from the PVC and Compounding Plants - the one respirator with trash under the valve is gimicked to give an easy example of an obvious defect and one that has been found in the plants. Point out this part of the SWP and quickly read it. C Putting on a full face mask. Best to use th c can i.stcr mas k to show them. Remember the easier way to show i s t o let all s t ra full out, grasp top straps with both hands, St ick chin in fa ce .piece, pull straps over head, and then tight on 'straps , etc (remember about taking off bottom canister s ea 1) - AP00050974 1 D. Quick references to cleaning respirators near back of both SWP's. Show with cartridge respirator about unscrewing cartridges before washing. Mention that 0S11A says that the foreman must inspect respirators to be sure that no defects exist and that they are clean. E. Practice on using respirators. Each man puts on a cartridge respirator, a canister respirator, and an airline respirator. For the airline respirator, he hooks up all connections on the two hoses and unhooks them (this is important!). AP00050975