How to Make a Respirator Program and Calculating the Cost

How to Make a Respirator Program and Calculating the Cost Dan Curts CIH,ROH,CRSP

Goals Understand how to develop a respiratory protection program Understand regulatory requirements Understand the costs related to the selection and implementation of a respiratory protection program

Legislative Overview Federal Jurisdiction Federal Labour Code NIOSH Provincial Jurisdiction OHS Act CSA Z94.4-93/02

APFs Head Protection Eye & Face Protection As of 4Q 08 Fed = CSA/82 Fed = CSA/77 Fed = CSA/82 PEI/NS/NFLD CSA-02/93/02 CSA CSA BC CSA/ANSI/JIS CSA/ANSI CSA-02 CSA/ANSI CSA NIOSH CSA CSA CSA-02 CSA CSA/ANSI NIOSH CSA/ANSI CSA or Equiv. CSA-93/ ANSI CSA/ANSI CSA NB CSA-93 ANSI (CSA Z94.1considered equivalent) CSA

As of 4Q 08 Canadian Regulations APF/Head/Eye BC AL SA MA ON QU PEI NS NFLD NB Fed APF BC Z94.4-02 NIOSH Z94.4-02 NIOSH Z94.4-93 or ANSI Z94.4-02 Z94.4-93 Z94.4-02 Z94.4-93 Z94.4-82 Head Z94.1-92 Z89.1-86 JIS T8131 Z94.1-92 Z89.1-03 Z94.1 Z94.1-05 Z89.1-03 Z94.1 Z89.1 Z94.1-86 Z89.1-92 Z94.1 Z94.1-92 Z94.1 Z89.1-97 Z94.1 Z94.1-77 Eye Z94.3-92 Z87.1-89 Z94.3-02 Z94.3 Z94.3-02 Z94.3 Or equivalent Z94.3-92 Z94.3 Z94.3-99 Z94.3 Z94.3-92 Z94.3-82

Terminology Respirator vs Mask Tight fitting NIOSH approved Quality Checked Minimum filter efficiency requirements Designed to filter particles incoming and outgoing Loose fitting No approvals No quality check required No filter efficiency Designed to stop large particles from hitting the person who is wearing the mask

What is a Respiratory Program? Respirator protection program is: A program that provides a framework for an employer and employees to ensure they meet legislative requirements in providing respirator protection.

What is the Goal of a Respiratory Program? The Goal is to: Protect the user from inhaling a hazardous atmosphere when engineering or administrative control measures are not practicable or not adequate during the course of his work

Respiratory Needs Assessment Hazard Identification Program Audit Sampling Strategy Maintenance Program ELEMENTS OF A RESPIRATORY PROGRAM Respirator Selection Fit Testing Program Development Training Medical Surveillance & Pre-screening

Negative Pressure Air Purifying Respirator By inhaling, a negative pressure is created in the respirator. Ambient air flows through a filter or cartridge, which removes the contaminants. The clean air continues into the respirator and then the lungs. Particle Filter Gas/Vapour Media

Cartridge or Filter Filter: Dusts, mists, fumes and fibers N/R/P classification Cartridge: Gases and vapours Specific to hazard

NIOSH Filter Classifications

Positive Pressure Air Purifying Respirators

Positive Pressure Air Purifying Respirators The motor/blower unit pulls the ambient air through a filter or cartridge, which removes the contaminants, and then forces the purified air into the breathing zone. Motor/ Blower Filter

Limitations of Air Purifying Respirators Not for use in atmospheres containing less than 19.5% oxygen Not for use in IDLH atmospheres or confined spaces Not for use when concentrations exceeds APF x OEL Do not use with facial hair, or other conditions that interfere with the seal between the face and the respirator Do not alter, abuse, or misuse the respirator

Supplied Air Positive Pressure Respirators The hood/helmet or face piece delivers the air to the users breathing zone (mouth/nose). The air travels from the valve to the Headgear through the Breathing Tube. The valve or connector allows the airline to attach to the breathing tube The air is fed through an airline to the user. *Air is supplied from a clean source: Bottle, compressor, pump etc.

Limitations of Supplied Air Approved for respiratory protection during entry and escape from oxygen deficient atmospheres, dust, mist, gases,and vapours at temperatures above - 25ºC, and below 71ºC. Approved only when compressed air cylinder is fully charged with air meeting the requirements of the CSA CAN3-Z180.1. When air is supplied through an air hose assembly you must not exceed 300ft, and be within the pressure range of 8 to 125 psig.

Definitions Assigned Protection Factor (APF): The estimated level of respiratory protection that would be provided by a properly fitting respirator. Hazard Ratio (HR): The estimated/measured airborne concentration of a substance divided by the occupational exposure limit. HR = Airborne Concentration Occup. Exposure Limit

Example Hazard Ratio A customer measures the amount of toluene in their environment and the results indicate it is 200ppm. HR of Toluene HR = 200ppm 50ppm HR = 4 Measured in the worker s environment OEL for Toluene Therefore the customer can use ½FP/MFR for respiratory protection in their work area

Assigned Protection Factors Nova Scotia Filtering Face Piece ½ Facepiece Negative Pressure Elastomeric Full Facepiece Negative Pressure PAPR with Hood PAPR with Tight Fitting PAPR with Loose Fitting CSA 10 10 QLFT 10 1000 1000 25 APF QNFT 100 02 CSA 10 10 100 1000 1000 25 APF 93 NIOSH APF QLFT 5 QNFT -10 10 QLFT/QNFT 10 (95/99filters) QLFT/QNFT 50 (100filters) 25 50 25

Example of Respirator Selection - Toluene Supplied Air Only option above IDLH Full Face APF = 100 (100 x 50 = 5000 ppm) PAPR loose fit APF = 25 (25 x 50 = 1250) ½ Respirator APF = 10 (10 x 50 = 500 ppm) Respirator Not Required SUPPLIED AIR REQUIRED ABOVE 500PPM 500 ppm Toluene IDLH 50 ppm Toluene Exposure limit 0.13 37 ppm Odour Threshold 0 ppm

Program Development: Roles and Responsibilities Employer Employee Program Administrator Supervisor

Employer Responsibilities To ensure that: The work site is evaluated and hazards eliminated or minimized. The appropriate respiratory protection is available to do the job. Workers are trained in the use of respirators. Respiratory equipment is properly maintained. Supervisors understand safe work procedures. Emergency work site procedures are developed and practiced by supervisors or workers.

Program Administration The program administrator shall: Administer the respiratory protection program Evaluate the effectiveness of the respiratory protection program Where necessary consult with other people knowledgeable in occupational health, occupational hygiene, safety, and industrial processes Ensure that all persons required to wear respirators receive written instruction, as appropriate

Supervisor Responsibilities To ensure that: Worker wears PPE and wears it correctly. Advises worker of danger, actual and potential. Every reasonable precaution is taken to Protect the worker.

Employee Responsibilities Ensure that: They are fit tested prior to wearing respirator if using a tight fitting respirator. They use only the respirator and cartridge/filter approved for job. They use the respirator as instructed They immediately report any problems to supervisor.

Program Records As part of any good program, records must be kept 93 required records fit testing training inspection 02 required records list of users training / fit testing selection health surveillance maintenance program evaluation

Medical Surveillance Goal is to detect health problems early when there is time to prevent permanent or debilitating injury.

Training Program Administrator Ensures employees are trained Annually or biannually training Program includes Legislation, respiratory hazards,respirator, emergency and controls Supervisor Inspection, maintenance

Training (CSA Z94.4-02)

Fit Testing Why do it? What is it? Who needs it? How often is it required?

Qualitative or Quantitative Testing Two Methods of Fit Testing Qualitative Quantitative

Inspection Before Use Check for, Cracks, tears, dirt and fatiguing Inhalation/exhalation values Head straps Filter gaskets Filter/cartridge

Cleaning, Maintenance and Storage Cleaning & Maintenance: Follow manufacturer procedures. Storage: Follow manufacturer storage procedures. Store in a manner which will protect them from: dust, ozone, sunlight, heat, extreme cold, excessive moisture, vermin, damaging chemicals and oil/grease.

Audit Audit each piece of the program

Part 1 is Complete Part 2 is Calculating the Cost of the Respirators

What is the BEST respirator to use based on cost?

Program Audit Respiratory Needs Assessment Provided the Legal requirements are met, a choice can then be made on respirator costs. Hazard Identification Sampling Strategy Maintenance Program ELEMENTS OF A RESPIRATORY PROGRAM Respirator Selection Fit Testing What is the BEST respirator to use based on cost? Program Development Training Medical Surveillance & Pre-screening

What influences your choice of PPE? Cost of Product Cost of Ownership Availability Mobility Wear Time Hazard Wages COPQ FBIE Ethnic Diversity Productivity Comfort Compatibility Facial Hair

Cost of Product Cost of Ownership or Cost of Car Cost of Operation

Cost of Product = Initial System Cost

Daily Cost of Product = Initial System Cost + Cost of Consumables + Cost of Repairs NOTE: Frequency and degree of maintenance have SIGNIFICANT impact on this.

Scenario #1 Woodcutting Inc. has identified 4 operators that require respiratory protection from dust. They also have issues with FBIE injuries. The air sampling shows that exposures are below 10X OEL. Calculate the daily cost of the respiratory protection

Daily Cost: MFR (Dust Application) Item Cost Each = List Typical Life (days) Cost / day Non-valved (8210) $ 180.25/160=$1.13 0.25 $4.52 Non-valved (8210) $ 180.25/160=$1.13 0.5 $2.26 Non-valved (8210) $ 180.25/160=$1.13 1 $1.13 Valved (9211) $255.75/120=$2.13 0.25 $ 8.52 Valved (9211) $255.75/120=$2.13 0.5 $ 4.26 Valved (9211) $255.75/120=$2.13 1 $ 2.13 Eyewear $5.00 20 $0.40 Range Non-valved Range Valved $1.53 - $4.92 $2.53 - $8.92 $3.23 ave $5.73 ave

Daily Cost: EFR 1/2 & FF Facepiece Dust application Item Cost Each = List Typical Life (days) Cost / day ½Facepiece $277.45/10=$27.75 120 $0.23 Filter $225.02/50=$4.50 1 $4.50 Eyewear $5.00 20 $0.40 Total $5.13 Full Facepiece $572/4=$143 120 $1.19 Filter $225.02/50=$4.50 1 $4.50 Total $5.69

Daily Cost: Head Mounted PAPR (Dust Application) Item Cost Each = List Typical Capitalized? Cost / Life day (days) Head Piece $ 1032.52 600 $ 1.72 Main Filter $199.04 5 =$39.81 20 $ 1.99 Visor $152.09 10=$15.21 20 $ 0.76 Face seal $52.76 10=$5.28 10 $ 0.53 Temple Seals $47.77 10=$4.78 20 $ 0.24 Head Seals $63.00 125 $ 0.50 Comfort band $154.03 10=$15.40 20 $ 0.77 Total $ 6.51

Daily Cost: Head Mounted SA (Dust Application) Item Cost Each = List Typical Life (days) Cost / day Hood $312.28 10=$31.23 5 $6.25 Breathing Tube $81.41 125 $0.65 Regulator $185.74 1250 $0.15 Belt $52.51 125 $0.42 Filter panel $4899.25 1250 $3.92 Filter panel cal + maintenance Cal$150+filters$183. 75 = $333.75 Capitalized 120 $2.78 SA Hose (25 ft) $144.45 250 $0.58 Air cost $2/day @ 5 /KWhr $2 Eyewear $5.00 2 $0.40 Total $17.15

Scenario #2 Paint Spraying Ltd. has identified 2 operators that require respiratory protection from vapours and mists. They also have issues with skin and face contact with the paint. The air sampling shows that exposures are 8X OEL for the combined solvent vapour exposure. Fortunately there are no isocyanates in the paints. Calculate the daily cost of the respiratory protection

Daily Cost: MFR (Vapour & Mist Application) Valved Valved Valved Range Non-valved Range Valved Eyewear Total Item Non-valved Non-valved Non-valved $ $ $ $ $ $ Cost Each = List $5.00 Typical Life (days) 0.25 0.5 1 0.25 0.5 1 $ $ $ $ $ $ 20 $0.40 Cost / day Not Allowed as No Gas or Vapour protection

Daily Cost: EFR 1/2 & FF Facepiece (Vapour & Mist Application) Item Cost Each = List Typical Life (days) Cost / day ½Facepiece $277.45/10=$27.75 60 $0.46 Filter $678.03/30=$22.60 1 $22.60 Eyewear $5.00 20 $0.40 Total $23.46 Full Facepiece $572/4=$143 60 $2.38 Visor Tearaways $152.48/100=$1.52 0.5 $3.02 Filter $678.03/30=$22.60 1 $22.60 Total $28.00

Daily Cost: Belt Mounted PAPR (Vapour & Mist Application) Item Cost Each = List Typical Life (days) Cost / day Head Piece $443.33 600 $0.74 Cartridge $580.56/6=96.76 1 $96.76 Visor $188.89/10=$18.89 30 $0.63 Face seal $80.94/5=$16.19 30 $0.54 Visor Tear offs $37.99/25=$1.52 0.5 $3.04 Comfort Belt $143.10 600 $0.24 Breathing Tube $105.22 250 $0.42 Battery Charger $133.52 600 $0.22 Power Cord $135.96 250 $0.54 Battery $477.78 600 $0.80 Sweat Band $47.27/10=$4.73 10 $0.47 Total $104.40

Daily Cost: Head Mounted SA (Dust Application) Item Cost Each = List Typical Life (days) Cost / day Rigid Head (L501) $433.33 600 $0.72 Breathing Tube $105.22 125 $0.84 Regulator $187.90 1250 $0.15 Tearaways $127.48/100=$1.27 0.5 $2.54 Filter panel Filter panel cal + maintenance $4899.25 Cal$150+filters$183. 75 = $333.75 1250 Capitalized 120 $3.92 $2.78 SA Hose (25 ft) $144.45 250 $0.58 Air cost $2/day @ 5 /KWhr $2 Eyewear $5.00 2 $0.40 Total $13.93

We have considered the cost of product per day. Have we considered all costs?

Cost of Ownership Cost of Product + Cost of Performance Cost of Ownership Productivity Employee Churn Eye Injuries Insurance Costs Quality

Summary There are 10 elements to a Respirator Program Selection of the best respirator is complex with multiple factors to be considered including Cost of Ownership

Total Program Cost per Year

Respiratory Needs Assessment Hazard Identification Program Audit Don t forget to include Cost of Ownership Sampling Strategy Maintenance Program ELEMENTS OF A RESPIRATORY PROGRAM Respirator Selection Fit Testing Program Development Training Medical Surveillance & Pre-screening

Thank You!