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Developing an OSHA Compliant Respirator Program

This webinar provides a brief overview of the procedures for implementing a respiratory protection program that meets the requirements of the OSHA Respiratory Protection Standard. It covers the elements of a written program, resources for additional information, and the classification of air-purifying and air-supplied respirators. The limitations and requirements of different types of respirators are also discussed.

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Developing an OSHA Compliant Respirator Program

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  1. Developing an OSHA Compliant Respirator Program Stan Liang, CIH, CSP, CET KTA-Tator, Inc.

  2. Brief overview of the following: Procedures for implementation of respiratory protection Requirements of the OSHA Respiratory Protection Standard Elements of a written respiratory protection program Resources for additional information Respiratory Protection Webinar Objectives

  3. Respiratory Protection • Last line of defense in protecting employees from harmful dusts, mists, gases and vapors • Feasible engineering controls or work practice must be implemented before the use of respiratory protection can be considered • Job rotation not permitted by some OSHA standards

  4. Engineering Controls • Vacuum shrouded power tools • Ventilation • Wet surface preparation methods • Substitution

  5. Respiratory Protection • Must be selected in accordance with procedures established in the respiratory protection program • Must be fitted, used, and maintained properly • Must be provided at no cost to the employee

  6. Maximum Use Concentration(MUC) • Key consideration in the selection of respiratory protection • Determined by multiplying the respirator’s Assigned Protection Factor (APF) times the Permissible Exposure Limit (PEL) • Level of airborne hazards should not exceed the MUC

  7. Respirator Classification • Air-purifying respirators • Air-supplied respirators

  8. Air-Purifying Respirators Uses mechanical filters or chemical cartridges to remove contaminants from the air that workers breathe

  9. Half Face APR • Assigned Protection Factor of 10 • Can not be used if respiratory hazards can cause eye irritation

  10. Full Face APR • Assigned Protection Factor of 10 or 50 • Protection factor depends on fit test method

  11. Powered Air Purifying Respirator • Uses battery operated blower • APF ranges from 25 to 1000 • Loose fitting hood or helmet type may be assigned to workers unable to wear tight fitting air purifying respirators

  12. Filter Selection for Toxic Metals • HEPA cartridges must be used for toxic metal hazards • HEPA cartridges designated as N100, R100, or P100

  13. Filter Selection for Painting Operations • Organic vapor (black) cartridges for roller/brush application • Organic vapor (black) cartridges with mist pre-filter for spray painting

  14. Air-Purifying Respirator and PAPR Limitations • Can not be used in conditions considered immediately dangerous to life and health • Can not be used where oxygen concentrations are below 19.5% • Can not be used if concentration of respiratory hazards exceed the protection factor of the respirator

  15. Air-Purifying Respirator and PAPR Limitations • Cartridges have a limited service life • Cartridges have a limited shelf life • Personnel who have severe scarring or other conditions which prevent the mask from sealing to the face may not use tight fitting air-purifying respirators

  16. Air-Supplied Respirators Provides the wearer with a continuous supply of clean, breathable air delivered to a tight- fitting facepiece or loose-fitting hood

  17. Supplied Air Respiratory Protection • Assigned Protection Factor up to 10,000 (depending on the type of respirator) • Tight fitting full face air line with auxilliary SCBA can be used in confined spaces with IDLH atmospheres

  18. Air-Supplied RespiratorLimitations • Length of air line must not exceed 300 feet • Line may kink, be cut, or be entangled • Line may become contaminated

  19. Air-Supplied Respirator Limitations • Use only air line, vortex, and other equipment specified by the manufacturer • Pressurize the air line in accordance with manufacturer specifications • Air line couplings must be compatible with breathing air systems only

  20. Air-Supplied RespiratorLimitations • The compressed air bottle for the escape SCBA must be hydrostatically tested in the following intervals: • Every 3 years - aluminum wrapped with fiber glass • Every 5 years - steel • Supplier of breathing air must certify in writing that breathing air is Grade D quality

  21. Air-Supplied RespiratorLimitations • Grade D requirements: • 19.5% to 23.5% oxygen • Less than 10 ppm CO • Less than 1,000 ppm CO2 • Less than 5 mg/m3 hydrocarbons • Do not use pure oxygen as breathing air

  22. Air-Supplied RespiratorLimitations • Portable or self contained compressed air cylinders used as breathing air sources last from 30 minutes to 60 minutes • Escape SCBAs usually provide 5 minutes of air • A low pressure alarm must be provided (if using a breathing air cylinder)

  23. Abrasive Blasting Respirators Type CE • Required for abrasive blasting • Check with manufacturer if using for other applications • Provides a protection factor of 1,000 (selected makes and models) or 25 • Not for immediately dangerous to life and health atmospheres

  24. Inspection of Respiratory Protection • Respirators must be inspected before and after use

  25. Inspection of Respiratory Protection • Inspect facepieces for: • Excessive dirt or contamination • Cracks, tears or holes • Cracked, scratched, or improperly mounted facepieces (on full facepiece masks) • Cracked or broken air purifying element holders • Damaged threads/gaskets

  26. Inspection of Respiratory Protection • Inspect headstraps or head harness for: • Broken straps or headbands • Loss of elasticity • Broken or malfunctioning buckles and attachments

  27. Inspection of Respiratory Protection • Inspect facepiece interior for: • Foreign material • Cracks, tears, or distortion in valve material • Cracks, breaks, or chips in the valve body, particularly at the sealing surfaces • Missing or defective valve covers • Improper installation of valve bodies

  28. Inspection of Respiratory Protection • Inspect air-purifying elements for: • Incorrect cartridges/pre-filters • Loose connections/cross threading • Expired cartridge shelf life date • Cracks/dents on cartridge • Evidence of prior use

  29. Inspection of Respiratory Protection • Inspect breathing tube (if air line used) for: • Broken or missing gaskets or O-rings • Missing or loose hose clamps • Deterioration found by stretching hose and looking for cracks and tears

  30. Inspection of Respiratory Protection • Inspection of air line systems for: • Bottle on escape pack fully recharged • Cylinder for supplying breathing air fully charged • Breathing air in cylinder (if used) certified as Grade D • Pressure in air line as specified by manufacturer • Low pressure alarm functional

  31. Donning Respiratory Protection • Once the respirator is donned, the wearer should check that the mask is properly placed on the face and the straps are properly tightened • The positive or negative pressure check must be performed each time the respirator is donned

  32. Negative Pressure Seal Check

  33. Positive Pressure Seal Check

  34. Procedures for Use ofRespiratory Protection • Users of tight-fitting masks must not have facial hair that interferes with facepiece seal • Contact lenses may be worn with respiratory protection • Other PPE worn with respiratory protection can not interfere with the seal of tight fitting respirators

  35. Procedures for Use ofRespiratory Protection • Respirator users shall leave the work area when: • Workers need to wash their face and respirators to prevent skin irritation • Vapor or gas breakthrough is detected • Filters require replacement

  36. Cleaning RespiratoryProtection • Wipe interior/exterior of respirator with manufacturer approved towelette at the end of the shift • Use mandatory OSHA procedures when: • Respirator is heavily contaminated • Respirator is used by another person

  37. Respirator Storage • What is a good practice in this picture? • What mistakes are shown here?

  38. Respirator Storage • Do not store respirators in areas where they are exposed to the following: • Contamination • Direct sunlight • Dust • Extreme temperatures • Must be packed or stored to prevent deformation

  39. Repairing Respiratory Protection • Remove defective respirators from service • Make repairs in accordance with manufacturer recommendations • Use only manufacturer approved parts

  40. Medical Evaluations • Medical evaluations must be provided to wearers of respiratory protection before fit testing or use • Employees who refuse an evaluation can not be assigned to tasks where respirators are required • Provided by a physician or healthcare professional (within the scope of their license) • Evaluations are conducted by having the employee complete the questionnaire in Appendix C of the standard

  41. Medical Evaluations • Questionnaire must be administered in a time and place convenient to the employee • Translation of the questionnaire is required for non english speakers • Employees have an opportunity to discuss the questionnaire and results with healthcare professional

  42. Medical Evaluations • The employee must be provided with a copy of the medical determination • Information collected via questionnaires is kept strictly confidential

  43. Medical Evaluations • The medical determinations include the following information: • Limitations on respirator use • Medical fitness • Need for follow-up evaluations

  44. Medical Evaluations Evaluations (in addition to initial evaluation) provided if: • Employee reports signs or symptoms related to the ability to use a respirator • Health care professional or Respirator Program Administrator determines that the employee needs to be evaluated • Information from fit testing or program evaluation indicates the need for another evaluation • Changes in workplace conditions result in increased physical stress on the employee

  45. Fit Testing • Required annually for all tight fitting respirators • Must be performed for each make, model, and size worn • Another fit test is needed for a change in weight or other medical condition which could change respirator fit • Workers must be clean shaven and medically approved to be fit tested

  46. Qualitative Fit Testing • Must be performed in accordance with Appendix A • Several options permitted by OSHA

  47. Quantitative Fit Testing • Required only for full face air purifying respirators • Must be performed following procedures in Appendix A

  48. Elements of a RespiratoryProtection Program • Designation of a Respirator Program Administrator • Procedures for selecting respirators (hazard evaluation required) • Medical evaluations • Procedures for proper use (including written change schedules for gas/vapor cartridges)

  49. Elements of a RespiratoryProtection Program • Procedures and schedules for cleaning, disinfecting, storing, repairing, and maintaining respirators • Procedures for evaluating the effectiveness of the program

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