Course Duration: 60 Minutes

Burnt Mountain LLC. Learning Management System (BMLMS)

RESPIRATORY PROTECTION

  

Learning Objectives

• Requirements of a respiratory protection program
• Types of respirators and their uses
• Respirator selection based on the hazards and protection factor
• Respirator medical evaluation and fit testing requirements
• Proper use and cleaning of respirators

Course Outline

1. Introduction
2. The Respirator Program
3. Air-Purifying Respirators
4. Atmosphere-Supplying Respirators
5. Filters and Cartridges
6. Protection Factors
7. Fit Testing
8. Use and Maintenance
9. Summary

Introduction                             

• Respirators are the last line of defense against airborne contaminants
• Respirators are only effective if:
  - They are available.
  - The employees know which ones to use and how to use them.
  - The employees are medically approved for various types of respirators.
  - The respirator fits well and has an adequate seal.
  - Employees properly maintain and store them.
  

When to wear respirators:

• They are required when feasible engineering controls do not adequately remove or control the hazards for employees.
• They may be worn while engineering controls are being evaluated or implemented.

Respiratory hazards:                         

• Mists
• Gases
• Biological hazards
• Fumes
• Dusts and fibers
• Vapors
   

Contaminants come in either a particulate or chemical form.

The following are the types of hazards found in the workplace that may be controlled through the use of respirators:

• mists, which are droplets of liquid that are suspended in air, such as those generated in metal cutting or spray painting operations
• gases such as nitrogen and acetylene
• biological hazards, such as bacteria, fungi, or viruses suspended in air
• fumes, which are solid particles suspended in the air that were caused by the vaporization of material during activities such as electroplating, welding, cutting metals, or injection molding
• dusts and fibers, which are fine particles suspended in air, such as asbestos
• vapors, which are the result of chemical evaporation, such as the vapors formed from solvents at room temperature.

Respirator Program                          
Respiratory protection program creation:                        

• Conduct a hazard assessment.
• If respirators are necessary, a written program is required.
• Keep the program up-to-date to reflect changes.
• Provide respirators, training, and medical evaluations at no cost.

A program is not required if the only respirators that are used are filtering facepiece respirators on a voluntary basis. 

Conduct a hazard assessment to determine whether respirators are necessary or required for your facility. If they are, a full, written respiratory protection program must be created.

Once the written program has been created, keep the program up to date to reflect changes in workplace conditions that affect respirator use, and provide respirators, training, and medical evaluations at no cost to the employee as required.

Elements of the program:

• Program administration
• Standard operating procedures
• Proper respirator selection
• Hazard assessments
• Employee training
• Medical evaluations
• Fit testing
• Program evaluation
• Recordkeeping
• Availability of the written program

Selection of respirators:

• Identify and evaluate:
     - Hazards.
     - Contaminant properties.
     - User factors.
• Select sufficient models and sizes.
• Select a NIOSH-certified respirator.
• Exposure that cannot be identified or estimated is considered IDLH.

In order to select the appropriate respirators, first identify and evaluate the respiratory hazards workers are exposed to in the workplace. This includes identification of the contaminant’s chemical state and physical form. Also consider all user factors that affect respirator performance and reliability.

Select respirators of a sufficient variety of models and sizes so that the respirator is acceptable to, and correctly fits, the user.

The entire respirator assembly, including cartridges, filters, and hoses must pass certification tests in order to be approved. The National Institute of Occupational Safety and Health, or NIOSH, and the Mine Safety and Health Administration, or MSHA, are responsible for testing and approving respirators.
 
Where exposure cannot be identified or reasonably estimated, the atmosphere shall be considered immediately dangerous to life and health, or IDLH.

 

Medical evaluations:

• Respirator usage has a medical risk.
• Records must be maintained for duration of employment plus 30 years.
• Evaluations must be performed by a PLHCP.
• Medical evaluation possible results:
     - Approval for all use
     - Approval for limited use
     - Recommendation for a particular type
     - Request for further medical evaluation
     - No approval

Employee training:

• General topics:
     ‒The components of the program
     ‒Types and limitations
• In-depth training for each type:
     ‒Limitations
     ‒Types of contaminants
     ‒How to put on and take off
     ‒When to wear it
     ‒When to change cartridges
     ‒How to clean it for storage
• Frequency:
     ‒Prior to use
     ‒If there are any changes

Voluntary respirator use:

• Filtering facepiece respirators are the only respirators allowed to be used on a strictly voluntary basis.
• A written program, medical evaluations, and fit testing are not required.
• They may be supplied by the employer or employee.
• Employees must receive additional information:
     ‒Manufacturer’s instructions
     ‒Storage instructions
     ‒Information about certification and labels
     ‒The correct and incorrect environments to wear the respirators in

Filtering facepiece respirators, also called dust masks, are allowed to be used strictly on a voluntary basis. However, this type of respirator is the only one allowed to be strictly voluntary, and if respirators other than this type are used on a voluntary basis, appropriate elements of a written program are required to be implemented. 

For filtering facepiece respirators, a written program, medical evaluations, and fit testing are not required.

They may either be supplied by the employer or provided by the employee.

All employees who voluntarily use this respirator are to receive additional information either verbally or in written form. This additional information includes:

• the manufacturer’s instructions for use, cleaning, and maintenance
• instructions for storing the respirator in a specified location, in order to assure that employees consistently use the same respirator
• and the requirements for certification and labels.

In addition, employees must know the correct and incorrect environments to wear the respirators in. Respirators should only be used if they will protect against the specific air contaminants in the environment. For example, dust masks may be worn in areas where particulates are a respiration hazard, but they must not be worn as protection in environments that contain hazardous gases or vapors.

Program evaluation:

• Hazard assessments
• The selection of respirators
• Respirator appropriateness
• Fit testing
• Employee interviews
• Proper maintenance
• Employee observations
• Written program accessibility

Conduct fit testing to assure proper fit and use of respirators by employees.

Employees will be interviewed to assess the effectiveness of the program and to assure that employees are using respirators properly. Also, the review will include a discussion of the maintenance of the respirators.

Observe the employees’ use of respirators, and address any issues.

The evaluation will also check that a written copy of the current program is retained.

Recordkeeping:

• Medical evaluation records
• Fit testing records:
     ‒Employee information
     ‒Date of testing
     ‒Fit test type
     ‒Specifics of the respirator
     ‒Outcomes

Air-Purifying Respirators

Air-purifying respirators (APRs):

• Filter contaminants from the ambient air.
• Use a filter, cartridge, or canister.
• Must be chosen based on the hazards.
• May be full face or half mask.
• Seal against the wearer’s face.
• Require fit-testing.
  

Air-purifying respirators, or APR’s, provide protection against specific contaminants, by drawing in ambient air, removing specific contaminants using a filter, cartridge, or canister, and providing the clean, filtered air to the user’s breathing zone.
 
The respirators and cartridges must be chosen based on the hazards. For example, cartridges may provide particle filtration and liquid barrier.

APRs may either be full facepiece or a half mask. Each type provides a different protection factor against exposure.
 
APRs seal against the wearer’s face and require fit testing to verify that they are adequately protecting the user.

Do not use APRs in the following conditions:

• When contaminants or their concentrations are unknown
• If concentrations exceed maximum use
• Around gases or vapors with low sensory warning properties
• In high humidity
• In oxygen-deficient environments
• In IDLH environments

Immediately
Dangerous to
Life and
Health

Negative pressure respirator:

The air pressure outside exceeds the air pressure inside.

A negative pressure respirator is a respirator where the air pressure inside the facepiece is negative during inhalation. This means that air is pulled in through the filters during inhalation, supplying clean air to the breathing zone.

Positive pressure respirator:

The air pressure inside exceeds the air pressure outside.

A positive pressure respirator is a respirator with pressure inside the respiratory inlet covering that exceeds the ambient air pressure outside the respirator. A common type of positive pressure respirator is a powered air-purifying respirator.

Filtering facepiece:

The air pressure inside exceeds the air pressure outside.

• Negative pressure particulate respirator
• Largely made of the filtering medium

A filtering facepiece, or dust mask, is a negative pressure particulate respirator. The filtering medium is either an integral part of the facepiece or composes the entire facepiece.

Powered air-purifying respirators (PAPRs):

• They are mostly positively pressurized.
• They require an external air source for minimum air flow.
• They can be sometimes negatively pressurized.
• They do not require a fit test or the user to be clean shaven.
  

A powered air-purifying respirators, or PAPRs are considered to be positive pressure respirators under most operating conditions.
 
PAPRs require an external air source, usually a blower, to maintain a minimum air flow.
 
However, they can be over-breathed, which potentially makes them negatively pressurized for brief periods of time.

PAPRs are not tight-fitting and do not require a fit test or for the user to be clean-shaven.

Atmosphere-Supplying Respirators

Overview:

• The air source is independent of the ambient atmosphere.
  
  
• The categories are:
     ‒SARs.
     ‒SCBAs.
     ‒Emergency escape respirators.
• The main operating types are:
     ‒Continuous flow.
     ‒Demand pressure.
     ‒Negative pressure.
     ‒Pressure demand.

Atmosphere-supplying respirators supply the user with breathing air from a source independent of the ambient atmosphere.

The categories of atmosphere-supplying respirators are supplied-air respirators, or SARs, self-contained breathing apparatuses, or SCBAs, and emergency escape respirators.

The following are the main operating types of atmosphere-supplying respirators:

• Continuous flow respirators provide a continuous flow of breathing air to the respiratory inlet covering.
• Demand respirators or negative pressure respirators admit breathing air to the facepiece only when negative pressure is created inside the facepiece by inhalation.
• Pressure demand respirators maintain a positive pressure within the facepiece and also admit air to the facepiece when the positive pressure inside the face-piece is reduced by inhalation.

Typical system components:

• Compressor or cylinders
• Air delivery lines
• Air purification system
• Reserve air supply
• Carbon monoxide filter or alarm

The typical system components of atmosphere-supplying respirator include compressors or cylinder, air delivery lines, air purification system, reserve air supply, and a carbon monoxide filter or alarm for oil-lubricated compressors.

Supplied-air respirators (SARs):

• They deliver clean breathing air from outside the work area.
• The source of breathing air is not designed to be carried by the user.
• They are used in IDLH environments and emergency response situations.

Also called airline respirators, supplied-air respirators, or SARs, deliver clean breathing air from outside the work area. The source of breathing air is not designed to be carried by the user. Instead, the air is piped to the inlet through a hose connected to the facepiece.

This respirator is commonly used in IDLH environments and emergency response situations.

Self-contained breathing apparatus (SCBA):

• The breathing air source is carried by the user.
• They are used for:
     - Firefighting.
     - General industry.
     - Hazmat projects.
  

For self-contained breathing apparatuses, or SCBAs, the breathing air source is designed to be carried by the user.
 
They are used in firefighting, general industry, and hazmat projects. 
SCBAs have minimum quality air requirements. This requirements are outlined in the next slide.

Grade D Breathing Air Requirements:

Gases                                   Allowable concentrations
Carbon Monoxide (CO)                    < 10 parts per million
Carbon Dioxide (CO2)                     < 1000 parts per million
Condensed Hydrocarbons                < 5 milligrams per cubic meter
Noticeable Odors                            None

Specific components are required for the breathing air in SCBAs.

The concentrations of carbon monoxide, carbon dioxide, and condensed hydrocarbons must be controlled to prevent any hazardous concentrations in the breathing air. This chart has the allowable concentrations of each.

The moisture concentration in the breathing air must be less than sixty-six parts million for carbon monoxide scrubbing devices to work properly.

Escape-only respirators:

• They are used only during an emergency evacuation.
• They are not intended to be used on a routine basis.
• They do not require employees to be fit tested.

Emergency escape respirators are intended to be used only during an emergency to evacuate an area where an unplanned airborne contaminant is present.

They are not intended to be used on a routine basis, and they do not require employees to be fit tested.

Filters and Cartridges

Particulate air filters:

• These are the most common type.
• They have ratings based on efficiency of filtering.
     ‒ 95 = 95%
     ‒ 99 = 99%
     ‒ 100 = 99.97% (HEPA filters)
• There are additional ratings for oil.
     ‒ N = not recommended for oil mist
     ‒ R = oil mist-resistant
     ‒ P = oil-proof

The most common type of respirator is a particle filter respirator.
 
The filters have various ratings based on the efficiency of filtering out particulates of a certain size.
 
“Ninety-five” means a ninety-five percent filtering efficiency.
“Ninety-nine” means a ninety-nine percent filtering efficiency.
“One hundred” means a ninety-nine-point-nine-seven percent filtering efficiency.
 
These one-hundred-rated filters are high efficiency particulate air filters, or HEPA filters. These are at least ninety-nine-point-nine-seven-percent-efficient in removing particles that are point-three micrometers in diameter and larger.

Filter performance has additional labeling for contact with oil:
N means not recommended for oil mist.
R means oil mist resistant. R filters are single-use disposable filters.
P means oil-proof. P filters are reusable.

Canisters and filter cartridges:

• Have a filter, sorbent, catalyst, or a combination.
• Are selected based on the hazards.
• Remove specific contaminants from the air.
• Must match the respirator brand.
• Must be labeled and color-coded.

Canisters and filter cartridges are containers with a filter, sorbent, catalyst, or a combination of these items. Types that combine a filter layer with a chemical sorbent layer are typically referred to as stack filters.

They are selected based on the hazards, and each type removes specific contaminants from the air as they pass through the container.

Canisters and filter cartridges must match the respirator brand, since they are approved as a unit.

Canisters and filter cartridges must be labeled and color-coded with the NIOSH approval label. This label will include information, such as the level of protection against oil, filter efficacy, and the types of chemicals it will protect against. The label must remain legible and not be removed.

Service life:

• Service life is the length of adequate protection.
• Particulate filters remain serviceable until  breathing becomes restricted.
• Single-use filter facepieces must be disposed of after each use.
• Factors for determining useful life include:
     ‒Chemical warning properties.
     ‒Chemical concentrations.
     ‒Identity of the chemical.
     ‒Temperature and humidity.
• The service life is the period of time that a respirator, filter, sorbent, or other respiratory equipment provides adequate protection to the wearer.
   
  While particulate filters typically remain serviceable until breathing becomes restricted, single-use filter facepieces must be disposed of after each use.
   
  Sorbent materials have several different methods for determining useful life. The following factors may be evaluated:
• chemical warning properties such as sensory warnings of smell
• chemical concentrations
• the identity of the chemical being protected against
• and the ambient temperature and humidity, which may affect the performance of the sorbent material.
  

Cartridge replacement:

• Chemical cartridges become saturated.
• End-of-service life indicators (ESLI) are required for organic vapor and chemical cartridges. 
• If no ESLI is available, establish a replacement schedule.
• Replacement schedules are developed using:
     ‒Mathematical models.
     ‒Manufacturer's software.
     ‒Calculations.
     ‒Rules of thumb.

Assigned protection factors (APFs): 

• APFs reflect the degree of protection.
• They range from 10 – 10,000.
     ‒10,000 is the highest protection.
     ‒The most effective respirator is a SCBA with a protection factor of 10,000.
• APFs are assigned to generic types.
• They are used to determine the type needed.
• The APF is only valid if the fit test is passed.

Assigned protection factors, called APFs, are numbers assigned to the respirator that reflect the degree of protection offered by its style type. The assigned protection factor ranges from ten to ten thousand.

A protection factor of ten thousand is the most effective, meaning complete protection against respiratory hazards. The most effective respirator available is an SCBA with a protection factor of ten thousand.

APFs are assigned to generic respirator types, but every specific respirator will have variable protection based on the hazards, conditions, and fit.

APFs are used to determine the type of respirator needed to adequately protect workers from various exposure conditions.

The APF is only valid if the wearer passes the appropriate fit test for that respirator type.

Maximum use concentration (MUC):

• The MUC is the maximum use concentration of a specific contaminant for which a respirator may be used.
• MUC = permissible exposure limit (PEL) x assigned protection factor (APF).
  

PEL for benzene = 1 ppm

Respirator   Protection Factor   Equation   Maximum Use Concentration
Half face     10                           1 x 10        10 ppm
Full face      50                           1 x 50        50 ppm
PAPR           100                         1 x 100      100 ppm

The maximum use concentration, or MUC, is the highest concentration of an air contaminate that may be present without exceeding the exposure limits.

The MUC will vary based on the protection factor of each respirator.

MUC is calculated by multiplying the established permissible exposure limit for a specific contaminant by the assigned protection factor of a respirator, or PEL times APF.

For example, the PEL for benzene is 1 ppm. This is the maximum concentration of benzene that workers can be exposed to during a work day. The respirator used must limit the concentration that can reach the breathing zone to lower than this concentration.

As shown in the table, the half face respirator, with a protection factor of ten, has the lowest maximum use concentration.

The PAPR has the highest protection factor and therefore can be worn in higher benzene concentration environments while still protecting the worker.

Respirator Fit Test

Respirator fit:

• Proper respirator fit depends on the face-to-facepiece seal.
• Proper fit assures that the respirator is the most protective.
• This can be affected by the following:
     -Overall fit
     -Facial hair
     -Facial scars
     -Eyeglass temple bars
  

Proper respirator fit depends on the face-to-facepiece seal. If this seal is not maintained, contaminants can leak into the respirator and enter the breathing zone. Proper fits assures that the respirator is the most protective.

Thr effectiveness of the respirator is impacted by the overall fit, including the size and shape of respirator and the face, facial hair, facial scars, and eye glass temple bars.

Fit testing:

• Before using respirators, employees must be fit tested.
• The two types are:
     ‒Qualitative.
     ‒Quantitative.
• Fit testing must be completed:
     ‒Prior to initial use.
     ‒Annually.
     ‒When a different respirator is used.
     ‒If facial features change.

Fit testing must be conducted by a competent and trained individual.

Before an employee uses any respirator with a negative or positive pressure tight-fitting facepiece, the employee must be fit tested with the same make, model, style, and size of respirator that will be used.

There are two types of respirator fit testing, qualitative testing and quantitative testing.

The fit test must be completed:

• prior to initial use
• at least annually after the first test
• whenever a different respirator facepiece is used, whether there is a difference in size, style, model or make
• and if there is a change in facial features that could affect the seal.

Qualitative fit testing (QLFT):

• This tests the face-to-facepiece seal.  
• Test agents can be sensed at low concentrations.
• Testing agents include:
     ‒Irritant smoke.
     ‒Isoamyl acetate (banana oil).
     ‒Saccharine mist.
     ‒Bitrex.
• Use this testing only when contaminant levels are below 10 x PEL.

Qualitative fit testing, or QLFT, is a pass-fail method of testing the face-to-facepiece seal. This is a subjective test in which a test agent is presented and the tester is asked whether they can sense the test agent.

Test agents are strong-smelling or strong-tasting substances that can be sensed even at low concentrations.

Qualitative testing methods include irritant smoke, isoamyl acetate or banana oil, saccharine mist, and bitrex.

Regulations only allow qualitative tests for respirator use in atmospheres where airborne contaminant levels are no more than ten times the PEL.

Quantitative fit test (QNFT):

• It measures the fit rather than the seal.
• It compares particle concentration.
• An instrument numerically measures the amount of leakage.
• The results are expressed as fit factors.

Quantitative fit testing, or QNFT, is a more sophisticated method of determining the fit of a respirator. This method is used to measure how effective a particular respirator is rather than whether there is a seal present. This method compares the concentration of particles in the ambient air to the particle concentration within the respirator.

An instrument is used to numerically measure the amount of leakage into the respirator.

The results of these tests are reflected numerically and are called fit factors.

Use of Respirators

Respirator inspection:

• Intact and functional straps
• No cracks in the facepiece
• Proper cartridge assembly
• Intact, clean, and functioning valves
• Proper assembly of all parts
• Cleanliness
• Pliability of the facepiece

Respirators must be inspected before each use. Inspect your respirator for the following:

• intact and functional straps
• no cracks in the facepiece
• proper cartridge assembly
• intact, clean, and functioning valves
• proper assembly of all parts
• cleanliness
• and pliability of the facepiece.

Positive pressure check:

1. Cover the exhalation valve.
2. Lightly exhale.
3. Check for leaks.

Respirator users must perform two types of user seal checks each time the respirator is put on.

First, perform a positive pressure check.

• Cover the exhalation valve with the palm of your hand.
• Lightly exhale to create pressure inside the mask.
• Check for leaks in the form of air flowing out of the mask.

Negative pressure check:

1. Cover the cartridge intakes.
2. Lightly inhale.
3. Check for leaks.

For both checks, if any leaks are detected, adjust the mask and try again. If leaks continue, do not use the respirator.

Second, perform a negative pressure check.

Cover the cartridge intakes, typically with the palms.

Lightly inhale until the facepiece begins to collapse toward the face.

Check for leaks in the form of air flowing into the mask.

 

Respirators cannot be used:

• While using tobacco products.
• While using chewing gum.
• While eating or drinking.
• With facial hair.
  

Respirators cannot be used in the following circumstances:

• while using tobacco products
• while using chewing gum
• while eating or drinking
• and when the user has facial hair such as a beard or mustache that may interfere with the seal.

Employees must leave the respirator use area if:

• They need to wash their face or respirator facepiece.
• They detect contaminants, changes in
  breathing resistance, or leakage of the facepiece.
• They need to replace the respirator, filter, cartridge, or canister
• They experience dizziness, disorientation, or any other unusual symptoms

Maintain an appropriate surveillance of work area conditions and the degree of employee exposure.

Employees must leave the respirator use area in the following circumstances:

• if they need to wash their face or respirator facepiece
• if they detect contaminants, changes in breathing resistance, or leakage of the facepiece
• if they need to replace the respirator, filter, cartridge, or canister
• or if they experience dizziness, disorientation, or any other unusual symptom that could indicate possible exposure.

Cleaning and storage:

• Respirators must be cleaned before storage.
• Upon removal:
     ‒Remove and discard cartridges.
     ‒Wash your hands and face.
     ‒Disassemble and wash parts.
     ‒Reassemble and store.
• Respirators must be stored:
     ‒In a sealed container.
     ‒In a clean and dry location.
     ‒Away from chemicals.

In order to prevent the contamination of the storage container, it is necessary to clean the respirators between uses before they are placed into storage.

Upon removing tight-fitting respirators:

• Remove and discard the cartridges, if appropriate
• Wash your hands and face thoroughly
• Disassemble the respirator and wash all the parts thoroughly with soap and warm water
• Re-assemble and store the respirator properly

Reusable respirators must be stored, when not in use, in a sealed container and in a clean and dry location that is located away from areas where chemicals are used or stored.

Preventative maintenance:

• Replace worn and deteriorated parts.
• Only use parts and cartridges approved for the brand and type.
• Re-evaluate effectiveness when there are changes in the work area or exposure.

Preventative Maintenance

For the respirator to work effectively over time, preventative maintenance must be performed on a regular basis.

Replace worn and deteriorated parts as needed.

Only use parts and cartridges approved for your brand and type of respirator. Parts and cartridges are not interchangeable between brands and types.

Re-evaluate the respirator’s effectiveness when it may be affected by changes in work area or exposure.

 

Summary

• Respirators are a key element in protection from airborne hazards.
• Various types are available and must be matched to the hazards.
• Before using respirators, employees must be medically evaluated and fit tested.
• Training must be provided for the care, use, and limitations of respirators.
  

In summary, respirators are a key element in the protection of employees from airborne hazards.

Various respirator types are available, and they must be correctly matched with the specific contaminants and work environments employees will encounter.

Before an employee can be assigned a respirator, they must be medically evaluated to determine if they can wear the respirator safely. Then they must be fit tested to assure that the respirator fits them properly.

Training must be provided for the care, use, and limitations of respirators, based on the respirator types and the hazards associated with their usage.