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e 12, 1980 M. T. ANDERSON F. G. REITZ P. J. SNYDER Attached is an update draft of the Safety Order, "Respiratory Protection." Let's discuss on Wednesday, June 18 at 1 P.M. Attachment RPF:ikg B. P. FRUTIGER v LAM 004142 DPMC-10230 lehr \rk .c!; l'l L I.-:- T /: ,,G- 0 3-o 0 : UFAOVURTNG COMPLEX CliEMT CAL RESPIRATORY PROTECTION SAFETY S-34 PAGE 1 OF 9 JUNE 3, 1980 I. GENERAL Many types of respiratory protective devices are pro vided for routine and emergency conditions throughout the Complex. Each department in the Complex has respiratory equip ment available where the possibility exists for employees to be exposed to potentially hazardous concentrations of vapors, fumes, gases, dusts or mists. This order addresses the different types of respiratory equipment, selection' for specific tasks, personal limitations, some general precautions in the use of respiratory equipment, training responsibility, and work permits. Primary emphasis shouId be placed on engineering, administrative, or work practice controls. However, for tho?e situations where such measures are not feasible, or while they are being instituted *\vt j or evaluated, appropriate respiratory protection shooed be used. Each line manager is responsible for establishing and maintaining an effective respiratory protection program. This includes: . Developing written operating procedures gr u / r*o--use cf~ + e c r-t'o ** ^ ciclc.cLTUn and uc'a.of--re s p ^ y a t or s ^ . Providing for employee training in the use^ e-n^ limitations^of respiratory protection equipment ^ e]~-a--they ^r7i.rnena--fc-e--jobs i-ncy LAM 004143 DPMC-10231 KUSpi XAYOKY PROTECT ,-JN kAUrlY S-3 4 TACK 2 Or' 9 JUNE 3, 19S0 . Providing proper respiratory equipment; . Auditing the program to ensure continued effectiveness; Each employee is responsible for; . Using the respiratory protection equipment in accordance with instructions and training received; . Reporting any malfunction of the respirator to the* rcoponai-ole pcraon; and assuring that an adequate respirator-to-face fit is achieved each time the respirator is II. TYPES OF RESPIRATORY PROTECTION* 1 2 Each type of respiratory equipment has certain advan tages and disadvantages. These must be considered in relation to such conditions as the type material which will be encountered, concentration, length of exposure, personal limitations, etc. When questions occur in regard to the type respiratory protection for a particular job, consult the Safety and Industrial Hygiene Department. Respirators covered in this order fall into two general classifications: Air-Supplied Breathing Apparatus 1. Self-contained breathing apparatus (Scott Air-Paks, or similar) 2. Air-line breathing apparatus (fresh air masks) Air-Purifying Respirators 1. Canister masks .2 Chemical cartridge respirators LAM 004144 DPMC-10232 Kl'SP ] .;,VJ okY PROTECTION_ i. AGE 3 Or 9 _ _________________________________ ________vJU'.'K 3, 19S0_ 3. Particulate or dust respirators 4. Special air purifying respirators The air-supplied breathing apparatus provides creator , J<*ee * respiratory protection than air purifying rcspirators^^ffio iJeot^Ki l Paks are self-contained and provide protection for a limited period of time. Scott Air-Paks should be used in emergency conditions, or where mobility is necessary, and may be used for very short duration planned tasks. The air-line breathing apparatus (fresh air masks) should be used for jobs which are expected to require more than a few minutes to complete. The air-purifying respirators provide protection for specific materials, and thus their use is limited. Air-purifying respirators do not provide oxygen and must never be used in oxygen deficient atmospheres (below 19.5% v oxygen). Detailed information about the various types of respirators is presented in Appendix I of this order. Those persons studying this order for Respirator Training should read Appendix I in its entirety, before proceeding further. III. GUIDES FOR SELECTION ' A. The first step in the selection of respirators is to be familiar with the various types of respirators-, their intended use and their limitations. This knowledge can be gained by a review of Appendix I and training as outlined in Section VII of this order. B. Material Safety Data Sheets Each work area shall have available to all personnel a set of material safety data sheets (MSDS) for materials encountered in the area. The manager in each area will insure that personnel are aware of these MSDSs and how they are to be LAM 004145 DPMC-10233 KFLiFlFA'lCRY PPOYFC jN________ _____ _____ _ ._____ : : V S- J A PACE A OF 9 _________ JONE 3, Ij'oO used to determine the type of respiratory equipment for any specific material. C. Some individual standards such as vinyl ehlorldeashestos and lead have specific requirements regarding respirator selection.__Selection of respirators for these materials are covered in training_proarants for the_j= peciftc mater.ial to be handled. Personal Limitations , , / / <. ./ Note: 1. Prior para graph signif icantly changed -A----i--l e--molo--ve--e-s/-fr.w---ho----a---r-e------s---u---bject to the use of resp- irators be cJe&* skii'jc*' -Sm^/Ccc. are required to cm' ~-a^>j.e a4~c.n.--.v- e.n tr----'h-op."/ nq , pf--f/rt;----rrac~o^jp31i irt tile ~e a l_ c 11 L of' Incl-a-l hn-j r <7 --Vj/--e j/a ce. if .1 -TI f J it; i 11 i,i iii 1 n i--c.-.a Acceptable industrial hygiene practlce requires that respirators not be worn when conditions prevent a good face seal. .2 Since temple bars of glasses can cause "leakage" by the face mask, plain safety glasses should be removed when wearing full-face mask respirators. Personnel who require corrective (prescription) glasses can be fitted with special prescription glasses that fit inside a --------------------------------------------Aic~tpVe>, bfc --ky^re~e---pr,rc/;c C_ full-face mask. ^ao/sr.-ibid" .1 i(yu'x"~ue p? .jcLli^e -W. Wo/--< ?<Vn -- c-- vOe a rrK^--c r~ ce<fu j.iu'5~ Liu L- w-itriouL CVcv-i.f i on '-thO' wear in^f-/if rc-R-tyrt; f J--ate,--crM'i<----a--eertp-^^T-crr---------a * e tcJc-cl-,---------------------------4rrSTTS lll**ront an-.i-mrL iTtla L 'i.us^li srco. + ^ ^ rosy J-i a Lux liot be allUlvecl. 3. For purposes of respirator selection, all Shell personnel* 4 who are subject to the use of respirators will be quantitatively fit tested on an annual basis. ~/%tz ~*7T( e~~s^ e*ft*/e-c/ by Safety JZ~**<*br a / ,24. Personnel who are un / to obtain and demonstrate a tight LAM 004146 DPMC-10234 fit of a respirator mask-because of unalterable physical b - Job* no/ features shall i * ~-y*=- 31 lv di i- snpp 1 i oa--i. a Chi wy-- fUe u.*e / r'Cttp.Vft/o"*. im:nt, in--pr-eco-aic ii'.uuo-. ^ A]1 persons assigned to tasks requiring the use of respirators will be evaluated as to whether they are physically able to wear one An assessment of an individual's ability to use a respirator will be done during pro-employment and voluntary periodic medical exams^ Conditions which may compromise the safe use of a respirator include a punctured ear drum. A person with a punctured car drum shall use only the air-supplied breathing apparatus in pressure-demand mode along with ear plugs. This is suggested to remove the slightest chance .that contaminated air could be inhaled through the ear. E. A few typical tasks where respiratory equipment is mandatory: 1. Asbestos insulation removal: to protect against inhalation of asbestos fibers. A "dust respirator" is the appropriate mask selection (see Attachment VIII). .2 Entry into flare lines: to protect against inhalation of harmful gases or vapors. The air-supplied breathing apparatus in pressure-demand mode is the proper selection 3. Sandblasting: to protect against silica. The special air- supplied hood is used. 4. Where personal exposure to vapors, gases, dusts, or particu lates is above the permissible exposure limits (PEL) given by the Material Safety Data Sheets. The proper selection may be the air-line breathing apparatus, the self-contained broaihie apparatus, an appropriate cartridge or canister respirator, or a dust mask, depending on the duration of the task, le\/ol of LAM 004147 DPMC-10235 KiJbP f.1-Vj'OFY 1J RO'i'FC'j .. JN SAi r.iV G -34 PA'.' E 6 OF 0 ..ll'.'O-' 3, i o g F. A few typical tasks where respiratory equipment may be required depending on the material that will be encountered; 1. Gauging tanks 2. Sampling (laboratory and operations) 3. Installing isolation blinds 4 . Repairs on pumps and compressors 5. Personnel rescue 6. Painting 7. Catalyst handling 8. Fire fighting IV. MAINTENANCE OF RESPIRATORY EQUIPMENT A. Cleaning Each area of the DPMC will be furnished a satellite resoiraior storage cabinet. The cabinet will contain a supply of each type of respirator used in the area. The respirator service group will maintain the stock in the satellite cabinet with clean, sanitized and packaged respirators. All cleaned respirators will be sealed in plastic bags for futher pro tection. All cleaning, sanitizing, inspection, repair and packaging will be performed bv a respirator service group -----------------------------------------------------------ptrc/faei---------------------------------------------------------------- in centralized facility|for that purpose. B. . Air Bottles It is the responsibility of the^managef1 to specify the number of Scott Air Pak air bottles to be maintained for the assigned breathing equipment. A guide is one extra bottle for every three pieces of equipment. C Storage LAM 004148 The respirator satellite cabinet is the pri ary storage DPMC-10236 P r.-AVOixY P!!OVFC" N I'Y S-34 PAGE 7 OF 9 JENS 3, 1 ID location for all respiratory equipment. Respirators shall not be stored in tool boxes, tool lockers or any other common storage cabinet. Emergency respiratory equipment will be stored in a fixed location in specially designed storage cabinets or cases. D. Replacement, Repairs and Inspection. (The departments listed below shall be responsible for the items listed.) 1. The Safety and Industrial Hygiene Department a. Repairs to air-supplied breathing equipment. b. Replacement of canisters on canister masks.- c. Quarterly inspection of all emergency breathing apparatus. d. Fill small breathing air bottles, and check all breathing air bottles per Safety Order S-ll. 2. Operations, Maintenance, and Laboratory a. Change breathing air bottles. See Safety Order S-ll, Breathing Air. b. Change cartridge on chemical cartridge respirators. c. Monthly check of all emergency breathing equipment. d. Notify Safety Department for equipment repair. e. Documentation of canister mask use. f. Records and routine inspection of individually assigned respirators (See Attachment IX.). EQUIPMENT REQUIREMENTS A. Operations A canister mask or a self-contained breathing apparatus shall be available for each permanent operating job and each operations foreman position on the unit. B. Maintenance LAM 004149 DPMC-10237 RASP I RATORY PROTKC - j ON __ _ . ____ _ i vy 3-34 PAGE 8 OP 9 Jl'NE 3, 1930 Each zone supervisor shall have at least one air-line breathing apparatus. VI. GENERAL INSTRUCTIONS IN USE OF RESPIRATORS A. Before using any respirator, understand the correct way to use it. B. Check all fittings of the respirator to make sure they are tight. C. Always put on a respirator before entering a hazardous atmosphere. D. More detailed instructions for putting on respirators used at DPMC are contained in Attachment X. E. If the odor of gas is detected while using any respirator, leave the area immediately. VII. RESPIRATOR TRAINING A'. All personnel subject to the use of respirators will be trained in the use of that equipment. The required training is outlined in Attachment VI (Operations and Laboratory) and Attachment VII (Staff and Maintenance). The various training requirements are as follows: 1. All new employees subject to use of respirators. Initial training will be provided as part of new employee orientation, by the Industrial Hygiene and Safety Department. This training will include a review of this order arid items 5-8 of Attachment VI. The completed forms on each trainee will be retained by the Safety Department. 2. All operating personnel newly assigned to an operating area (regardless of prior experience). LAM 004150 DPMC-10238 . ' .i- ESP I FATOPY PRO'iECi ' _ _ '' r.'.OK 9 OF 9 JOKE 3, 19 SO Training will be provided per AHachiaent VI, end the completed form for each person will be retained by the operating department. 3. All maintenance personnel newly assigned to a maintenance area (regardless of prior experience). Training will be provided per Attachment VII and the completed form for each person will be retained by the Maintenance Department. 4. All operating and maintenance personnel will be retrained annually with the completed forms retained by the respective departments. This training shall include review of this order and as outlined by Attachment VI or VII. B. The manager for each operating area shall prepare a listing of materials that may require respiratory protection in each work area and use this list during the respiratory training. This list will also assist operating personnel in the proper preparation of work permits, insofar as respiratory protection is concerned. VIII. WORK PERMITS Operating personnel shall outline appropriate respiratory protec tion requirements for craftsmen as part of the owrk permit process. The materials that may be encountered which require the respirator will be specified on the work permit. IX. SELECTION OF BRAND AND TYPE OF NEW RESPIRATORY EQUIPMENT The Safety and Industrial Hygiene Department will select equipment to be purchased at DPMC from equipment with appropriate NJOSH/MESA certification. LAM 004151 DPMC-10239