osha respiratory protection program respirator... · • train your workers-required annually-some...

OSHA Respiratory Protection Program

SPFA Convention 2011

2 HONEYWELL - CONFIDENTIAL File Number

Respiratory Protection

Today’s Agenda• OSHA respiratory standards overview

- Concentration on 29 CFR 1910.134 for General IndustryRequirements of a Respiratory Protection Program

• Respirator Selection• Medical Evaluations• Hands on Fit Testing• Voluntary Use• Types of Respirators

- We will use North respirators for demonstrations


• Industry specific RegulationsConstruction (29 CFR 1926)Maritime (29 CFR 1915, 1917 & 1918)Confined Space (29 CFR 1910.146)

• Contaminant specific Regulations – some examples Asbestos (29 CFR 1910.1001 & 1101) Lead (29 CFR 1910.1025)

• General Industry for Respiratory: 29 CFR 1910.134 Appendix A: Fit Testing Appendix B-1: User Seal Checks Appendix B-2: Cleaning Appendix C: Medical Evaluations Appendix D: Voluntary Use

Occupational Safety & Health Administration

Your program must include all Standards that apply to your worksite and applications


• State OSHA standards – may be more stringent than the corresponding Federal OSHA requirements.

Occupational Safety & Health Administration

Your program must include all of your State’s OSHA requirements that are more stringent than

the Federal OSHA requirements

Alaska Michigan South Carolina Local & State employees only:

Arizona Minnesota Tennessee Connecticut

California Nevada Utah Illinois

Hawaii New Mexico Vermont New Jersey

Indiana North Carolina Virginia New York

Iowa Oregon Washington Virgin Islands

Kentucky Puerto Rico Wyoming

Maryland



• Government Agencies - Mandatory- OSHA: Occupational Safety & Health AdministrationUnder the Department of Labor (DoL)Monitors worksite safety

- MSHA: Mining Safety & Health AdministrationDepartment of LaborMonitors worksite safety at mine sites (mine sites only – smelting is

under OSHA)- NIOSH: National Institute for Occupational Safety and HealthUnder the Centers for Disease Control & Prevention (CDC) Tests and Certifies Respirators – 42 CFR Part 84OSHA requires use of NIOSH Approved respirators



• Consensus Standards, Organizations - Voluntary- ANSI: American National Standards Institute Sets performance standards for all kinds of products including personal

protective equipment (PPE). OSHA requires use of ANSI compliant PPE such as hard hats and eye

protection – but not respiratorsANSI Respirator Standard Z88 ANSI performance standards for respirators does not replace NIOSH.

Use by manufacturers is voluntary only. ANSI respiratory program standards does not replace OSHA. Use by

employers is voluntary only.- NFPA: National Fire Protection Association- ACGIH: American Congress of Government Industrial

Hygienists

OSHA requires use of NIOSH Approved respiratorsOSHA requires use of hard hats, eyewear and

other PPE that meet ANSI Standards


Respiratory Protection - Terms

• Terms & Abbreviations for Respirators- Filtering Facepieces: Disposables or Dust Masks- APR: Air-Purifying Respirator- PAPR: Powered Air-Purifying Respirator- SAR: Supplied Air Respirator- PDAR: Pressure Demand Airline Respirator- SCBA: Self-Contained Breathing Apparatus- EEBA: Emergency Escape Breathing Apparatus


Respiratory Protection - Terms

• Industry Terms & Abbreviations- PEL: Permissible Exposure Limit (OSHA)- REL: Recommended Exposure Limit (NIOSH)- TLV: Total Limit Value (ACGIH)- OEL: Occupational Exposure Limit- STEL: Short Term Exposure Limit - IDLH: Immediately Dangerous to Life and Health

- APF: Assigned Protection Factor- MUC: Maximum Use Concentration- Fit Factor: different than APF – we will go into detail later


Respiratory Protection – 29 CFR 1910

• Whenever possible engineer out the contaminant(s)• If that is not feasible, implement a Respiratory

Protection Program• Program must be written & include procedures for:

- Respirator Selection- Respirator cleaning, maintenance and repair- Emergency Procedures- Training- Medical Evaluations & Fit Testing- Other procedures that apply (e.g. cartridge change schedule,

process for ensuring Grade D air)• Must be administered by a competent Program

Administrator• Must be dynamic and evaluated on a regular basis



• STEP 1: Assign a Program Administrator- Person must know the worksite & its hazards- Person must understand basics of respiratory protection

that will be used at that worksite- Understand the requirements of OSHA’s Respiratory

Protection Standard that apply to that worksite

- Does not matter what other duties this person has. This is job #1 and OSHA will not cut any slack

Program Administrator must be competent in respiratory protection and know the worksite



• STEP 2: A complete worksite assessment- What are the contaminants?- What are their concentrations? Are concentrations above

the Permissible Exposure Limit (PEL)?- Are concentrations higher during specific times of the day,

or different areas of the worksite?- Document everything in writing!

• STEP 3: Whenever possible engineer out the contaminants. Examples:- Change your production process or the materials used in

production so no hazardous substances are created or become airborne.

- Increase the ventilation so any exposure is below the PEL- Limit the hours a worker is in area so his/her exposure is

below the PEL



• If the contaminants are above the PEL and you cannot eliminate the exposure through engineering controls, a Respiratory Protection Program is required.



• STEP 4: Setting up your Program- Must be written- Copy of your Program must be on file at the local site or

readily accessible at your main office or HQ- Made available to workers who request a copy - Site specific (not a “plug and play”)Must include everything at that site, BUT does not need to include

elements of Respiratory Protection that are not at that site. e.g. if you do not use supplied air respirators do not include it in Program

- Evaluate your Program Regularly You decide how often, but on a regular basis review the Program. Is it

working? Has anything changed that will affect respirator use?- Program must be DynamicUpdate whenever there are any changes. e.g. if a contaminant or

concentrations change, the Program must be updated.



• Your Program needs to include:- Process for selecting the right respiratorsNIOSH Respirator Decision Logic PEL x APF = MUC (will be explained in a later slide)

- Procedures for:Routine inspections of respiratorsCleaningMaintenance & repair StorageDisposal (see your local EPA for additional guidelines)

- Training workers on respirator useWhy respiratory protection is necessary The respirator’s limitationsHow to put on, use and care for their respiratorsWhat to do in an emergencyHow & where to store their respirators



• Your Program needs to include:- Medical Evaluations- Fit Testing- If allowed by employer, voluntary use

• Your Program may also need to include: - Cartridge Change Schedule- Procedure to ensure Grade D breathable air- Procedure for a confined space- Other elements of 29 CFR 1910.134 that apply to your

worksite



• Selecting the right respirator- Know the contaminants Are they particulate (dust, fume, mists), gases or vapors?

- Know the concentrations Are they above the Permissible Exposure Limit? If so, how much?

- Oxygen content <19.5% requires a supplied air system <16% is Immediately Dangerous to Life and Health (IDLH)

- Lower Explosive Limit (LEL) Are any concentrations, including O2 at or above the LEL

- Demands of the job e.g. will workers need to move around, eliminating use of an airline

system?- Are any of the contaminants also a eye irritant?Consider use of a full facepiece


Respiratory Protection – Selection

• NIOSH Decision Logic



• NIOSH Decision Logic



• Permissible Exposure Limit (PEL)- The maximum allowable concentration of a contaminant in

the air to which an individual may be exposed for a time weighted average for an 8 hour day, 40 hour work week.

- Translation: The max amount of a contaminant that a worker should breathe in one day. If he is exposed to more than the PEL than a respirator is required!

• Where to find the PEL- MSDS- NIOSH Pocket Guide



• NIOSH Pocket GuideHelpful booklet containing

information on chemicals• PEL, IDLH, etc.• Respirator recommendations • Chemicals’ properties• Target organs and other

medical side effects



• Assigned Protection Factor (APF)- The workplace level of respiratory protection that a

respirator or class of respirators is expected to provide to employees when the employer implements a continuing effective respiratory protection program as specified by 29 CFR 1910.134

- Translation: How much a type of respirator (air-purifying ½ mask, airline hood, etc.) will protect a worker when used correctly. The higher the APF the better the protection.



•Assigned Protection Factors

Respirator Assigned Protection Factor

APR Half Masks – includes disposables 10

APR Full Facepieces 50

PAPR Half Masks 50

PAPR Full Facepieces 1,000

PAPR Loose Fitting Facepiece 25

PAPR Helmet / Hood 25 or 1,000 if Manufacturer can provide data.

SAR Half Mask – Cont. Flow 50

SAR Full Facepiece – Cont. Flow 1,000

SAR Loose Fitting Facepiece 25

SAR Helmet / Hood 25 or 1,000 if Manufacturer can provide data.

SAR Half Mask PDAR w/out escape 50

SAR Full Facepiece PDAR w/out escape 1,000

PDAR with escape or SCBA – Demand Mode 10,000 maximum



•Assigned Protection Factors- North PAPR and Supplied Air

hoodsTested internally by NorthAll hoods (Primair Plus and 85300 Series) passed fit test criteria to meet APF of 1,000 by demonstrating a fit factor >10,000



• Maximum Use Concentration (MUC)- The maximum atmospheric concentration of a hazardous

substance from which an employee can be expected to be protected when wearing a respirator, and is determined by the assigned protection factor of the respirator or class of respirators and the exposure limit of the hazardous substance.

- Translation: The max. concentration of a specific contaminant allowed at a specific site, for the specific type of respirator that is being worn.



• ExampleDimethylphthalate’s PEL = 5 mg/m3 (IDLH is 2,000)

PEL x APF = MUCPermissible Exposure Limit of 5, multiplied times Assigned Protection Factor of 10 for half masks equals that specific work site’s Maximum Use Concentration of 50 mg/m3. e.g. If that work site’s concentration for Dimethylphthalate is above 50 mg/m3 a half mask can not be used!



•ExampleDimethylphthalate’s PEL = 5 mg/m3 (IDLH is 2,000)

Other Maximum Use Concentrations:

<5 mg/m3 Under PEL – no respirator required

5 mg/m3 to <50 mg/m3 Half Mask (APR)

50 mg/m3 to <125 mg/m3 Loose Fitting Facepiece (PAPR or SAR)

125 mg/m3 to <250 mg/m3 Full Facepiece (APR); Half Mask (PAPR or SAR)

250 mg/m3 to <2,000 mg/m3 Full Facepiece or Hood (PAPR, SAR)*; or PDAR without escape

2,000 mg/m3 to <10,000 mg/m3 PDAR with escape or SCBA



• Procedures for:- Routine inspections of respiratorsMust be performed each and every time worker enters a

contaminated areaMust be performed after respirator is cleaned and reassembledDo you want additional spot inspections?

- Cleaning, maintenance & repairWill workers be responsible for their own respirators?Will you assign a person or a team to maintain all respirators?

- StorageMust be stored in a clean, contaminant free areaWill workers be responsible for storing their own, or will you have a

centralized place?- Disposal See your local EPA guidelinesRestrictions for certain contaminants, e.g. lead and asbestos



• Train your workers- Required annually- Some workers may need additional training – they just don’t

seem to get it. • Training needs to include

- Why respiratory protection is necessaryMake sure workers understand this is for their health

- The respirator’s limitations Air-purifying respirators may allow some contaminants through at

area of seal Air purifying respirators restrict breathingOnly an SCBA provides 100% assurance of 100% protection

- How to put on, use and care for their respirators- What to do in an emergency If the respirator fails, they have contaminant breakthrough, etc.

- How & where to store their respirators


Respiratory Protection – Medical Evaluations

• OSHA Procedures- Employer shall identify a physician or other licensed

health care professional.- The Medical Evaluation shall obtain the information in

Appendix C.- The employer shall ensure that a follow-up medical

examination is provided for an employee who gives a positive response to questions 1 through 8, Section 2.

- The follow-up exam shall include any medical tests, etc the PLHCP deems necessary.



• Medical Evaluations are only required: when a worker is first required to wear a respirator; if there is a change in the type of respirator, going to a higher

level (e.g. changing from a half mask to full facepiece); if there is a change in the worker’s health, or worker had an

illness that will affect ability to wear a respirator (e.g. worker had pneumonia); and if there is increased physical activity during respirator use (e.g.

going from sedentary job [low breathing rate] to one requiring more movement [medium or heavy breathing rate]



• Good practices, above & beyond OSHA minimum- Having everyone medically evaluated annually assures

employers that everyone is still medically fit to wear respirators, and covers the eventuality that a worker “forgets” to inform supervisor of a change in his/her medical condition.


Respiratory Protection – Fit Testing

• To determine if a specific mask fits an individual’s face.


• Loose fitting hoods are NOT fit tested

Loose fitting hoods do not require fit testing

Tight fitting hoods require fit testing.




Qualitative Fit Test (QLFT)- Pass / Fail: You know whether or not the mask fits, but not

how well it fits. Irritant Smoke (stannic chloride) Bitrex Saccharine Isoamile Acetate (banana oil)



Qualitative Fit Test (QLFT)

QLFT Pro Con

Irritant SmokeOV/AG/P100Have to have a P100Never, ever use a hood

•Breakthrough causes an immediate reaction – a cough

tough to fake it•Easy test to administer

•Heavy smokers may not be sensitive•Some are concerned about Stannic Chloride (when used properly it is under the PEL)

BitrexN95Subject is under a hood

•Test Solution is very bitter, difficult to fake•The QLFT used for N95 filters like the 7130N95 & the CFR-1

•The Sensitivity Solution can leave a lingering bitter taste in the mouth –confusing.•Very long test, difficult to administer

SaccharineParticulate FilterSubject is under a hood

•Easy to fake•Very long test, difficult to administer•Heavy consumers of diet products may not be sensitive.


Quantitative Fit Test (QNFT)- Provides an actual number, a fit factor, that tells exactly how well a

specific mask fits on any one individual’s face. PortacountDynatech (Controlled Negative Pressure) Aerosol (done in a Fit Test Chamber)




When to perform QNFT versus QLFT:½ mask APR if used @ or below MUC (10 x PEL) Qualitative or Quantitative Fit Test

Full Facepiece APR if used @ or below 10 x PEL Qualitative or Quantitative Fit Test

Full Facepiece APR if used @ or below MUC (50 x PEL) Quantitative Fit Test Only

PAPR or Continuous Flow Supplied Air ½ or full facepiece @ or below MUC Qualitative or Quantitative Fit Test

PAPR or Continuous Flow Supplied Air tight fitting hoods @ or below MUC Qualitative or Quantitative Fit Test

PDAR, SCBA if used @ or below MUC Qualitative or Quantitative Fit Test

PDAR with escape or SCBA that will be used in IDLH environments Qualitative or Quantitative Fit Test


• Fit testing is required:- the first time a worker is issued a respirator;- annually thereafter;Can be on anniversary of each employee’s initial fit test or all

employees at once, once a year

• Also required when:- if the worker is issued a new type or model of respirator;Changing from ½ mask to full facepiece, or vice versaChanging from one brand to another – no exceptions!Changing from one brand’s model to another if there is a difference in

material, design or other characteristic that affects fit- if the worker’s facial features changed; Lost or gained a lot of weightNow has denturesNew scar or other deformity



• Do NOT fit test someone:- if the person has not had a Medical Evaluation clearing that

person to wear a respirator;- if the person has any facial hair that comes between the seal

of the facepiece and face, even a stubble; or- the person is uncomfortable or anxious about putting a

respirator on.



• Facial hair paragraph from the Appendix:“The test shall not be conducted if there is any hair growth between the skin and the facepiece sealing surface, such as stubble beard growth, beard, mustache or sideburns which cross the respirator sealing surface. Any type of apparel which interferes with a satisfactory fit shall be altered or removed.”



• Procedure1. Individual being fit tested is allowed to pick the most

acceptable respirator from a significant number of models.

2. He/she is shown how to put on and position the mask. A mirror shall be available to assist the person.

Any instruction shall be a review – not the initial training.3. Inform the individual on options, etc., and instruct

him/her on how to make the best selection. 4. Assess the comfort & adequacy of fit.5. Individual performs a user seal check6. Give the individual the opportunity to select a different

respirator if the first respirator is unacceptable.



• Procedure7. The respirator to be tested shall be worn at least five

minutes prior to the test.8. The individual shall wear any other PPE that may be worn

during actual respirator use, and could interfere with the fit of the mask.

9. The respirator may not be adjusted during the fit test exercises.



For Qualitative Fit Tests• Each exercise is performed for 1 minute.

1. Normal Breathing2. Deep Breathing3. Turning head side to side4. Moving head up and down5. Talking (or recite the Rainbow Passage)6. Bending Over7. Normal Breathing

• Passing a Qualitative Fit Test The person may not have any reaction or sense the fit test

challenge agent (Irr. Smoke, Bitrex, etc.) If the person has a reaction, consider the test a failure.

• Reposition the mask• Try a different size



For Quantitative Fit Tests• Exercises, except 6, are performed for 1 minute.

1. Normal Breathing2. Deep Breathing3. Turning head side to side4. Moving head up and down5. Talking (or recite the Rainbow Passage)6. Grimace by smiling or frowning – for 15 seconds7. Bending Over8. Normal Breathing

• Passing a Quantitative Fit Test The TSI Porta-Count® indicates “PASS” The total Fit Factor will be supplied by the Porta-Count. The

minimum Fit Factor values must be:• APR ½ masks: 100 (10 x the APF of 10)• APR full facepiece: 500 (10 x the APF of 50)• SAR & PAPR ½ masks: 500 (10 x the APF of 50)• SAR & PAPR full facepieces: 10,000 (10 x the APF of 1,000)• PDAR in demand mode: 10,000 (10 x the APF of 1,000)• SCBA & combo PDAR: 100,000 (10 x the APF of 10,000)



• QNFT or QLFT - stop the test if– the person exhibits difficulty breathing during the tests.

Refer the person to a physician or other licensed health care professional;

– the person becomes anxious, exhibits signs of claustrophobia, or has any other concerns about continuing;

or– you are performing the Irritant Smoke Test and the

person has had at least two breakthroughs.



Time for hands on Fit Testing

Qualitative Fit Test Exercises

• Normal Breathing• Deep Breathing• Turning head side to side• Moving head up and down• Talking (Rainbow Passage)• Bending Over• Normal Breathing



• Voluntary use of respirators- Respirators may be allowed on a voluntary basis- It is voluntary if

contaminant concentrations are under the PEL;AND respirators are not required by the employer,



• Voluntary use of respirators- A Respiratory Program is still required, even if use of

respirators is voluntary- Employers may elect to NOT allow voluntary use of

respirators

Exception for disposables (filtering facepieces) “Exception: Employers are not required to include in a written

respiratory program those employees whose only use of respirators involves the voluntary use of filtering facepieces (dust masks).”



• Voluntary use of respirators

Voluntary Use(below the PEL)

Required Use(at or above the PEL, orRequired by employer)

Filtering Facepieces(dust masks)

Provide a copy of Appendix D Complete Respiratory Program

Elastomeric Facepieces Provide a copy of Appendix DRespiratory Program:

•Medical Evaluation•Cleaning•Maintaining•StoringFit testing is NOT required

Complete Respiratory Program



• Voluntary Use of respirators- Myths & misconceptionsUse of single strap masks eliminate need for a Respiratory

ProgramNo! In fact OSHA frowns on the use of single strap masks, even on a voluntary basis.Employees can insist on having a respirator

No, if the concentrations are under the PEL, it is up to the employer whether use of respirators will be allowed.Employers must provide a respirator at no charge

No, respirators must be provided at no charge to employees only if their use is required by OSHA or the employer.



• Your Program for voluntary use needs to include:- Medical Evaluations- Fit Testing- If allowed by employer, voluntary use

• Your Program may also need to include: - Cartridge Change Schedule- Procedure to ensure Grade D breathable air- Procedure for a confined space- Other elements of 29 CFR 1910.134 that apply to your

worksite


Air-Purifying Respirators




• APR Advantages

Lowest upfront cost

Simple to use

Most workers are very familiar with disposable style

•Economical

•Less training required

•Greater worker acceptance by non-respirator users



• APR Disadvantages

Cartridges & filters need replacing

Lowest protection factor

•Increased long term cost

•Limited to 10 X PEL



Powered Air-Purifying Respirators



• PAPR Advantages

Continuous flow of air to the worker

•Greater comfort

•Workers feel cooler, especially in hot work environments



• PAPR Advantages

Blower facilitates the flow of air through the filters or cartridges

•Workers are not fighting breathing resistance – less worker fatigue



• PAPR Advantages

Higher protection factor than air-purifying respirators

•Workers can enter and work in areas with higher contamination levels



• PAPR Advantages

Hoods do not require fit testing

•Can be worn by workers with beards or other problems with tight fitting facepieces (scars, dentures, etc).



• PAPR Advantages

Less upfront cost than Continuous Flow Respirators

•Economical choice without sacrificing comfort and protection



• PAPR Advantages

No hoses to drag around and limit workers’ mobility

•Workers have the freedom of movement. Not limited to 300 feet.



• PAPR Disadvantages

Cartridges & filters must be changed

Battery must be recharged

•Additional maintenance costs not found with Supplied Air

•Continuous use limited to battery’s service life



Supplied Air Respirators



• Supplied air system- A respirator- An air supply Pump;Compressor; orCylinder



• The respirator must have- Facepiece, hood or helmet- Breathing Tube may be a Y connector like our CF2007

- Male Coupler [on breathing tube]- Female Coupler [on hose]- Hose(s)



• The respirator may also include- Couplers between hose lengths- Vortex tube (a.k.a. air conditioner)- Flow control valve- Cartridges and/or filters

But only if NIOSH approved in that configuration



• Air source- Defined as that point which the hose of the respirator

connects to the air supply system• Air supply

- A supply of air (contained or supplied from a remote source of ambient air)

- Filtration system to assure Grade D or better- Pressure Gauge



• Air Supply Systems- A supply of air (contained or supplied from a remote source

of ambient air) Pump – supplies air by pumping ambient air from a remote source.

Size is measured in horse power (HP)Compressor – supplies air by compressing air to a pressure greater

than surrounding air, and forcing that pressurized air to the respiratorCylinder – self-contained air under pressure



• Putting together a supplied air system- Air supply Pump or compressor - mandatory Filtration system mandatory with compressor

- Air sourceHard connection or quick connect couplers

- Respirator, components required per the NIOSH approvalHose or hosesMale and female quick connect couplers Breathing tube Facepiece or hood


Maintenance and storage

• Part of a respiratory program

• Administrator should set the agenda on how often respirator should be cleaned.

• A quick daily cleaning is a good practice.

• Always store it in a clean and dry area.


Example of not maintained correctly!


Accessories to protect the integrity of respirator!

osha respiratory protection program respirator... · • train your workers-required annually-some...

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