Title: Respiratory Protection Site Procedure Preparer: Brandon Walker Function: Ecology & Safety No.: 13.14 Page: 1 of 15 Reviewed: 7/10/16 Effective: 7/15/16 Supersedes: 10/09/12 Owner: Approver: Judy K Brinkman James Emch Site Manager EHS Team Leader (Signature on File) (Signature on File) 1. PURPOSE BASF is committed to eliminating employee exposure to chemical and physical hazards through the use of engineering and administrative controls. In the event that engineering and administrative controls are not feasible the requirements established in this procedure will ensure BASF employees are adequately protected. This procedure addresses the proper selection, use, cleaning, maintenance and storage of respirators. 2. SCOPE This procedure applies to the BASF Corporation Kankakee, Illinois plant site. 3. DEFINITIONS Immediately Dangerous to Life and Health (IDLH) An atmosphere that poses an immediate threat to life; would cause irreversible adverse health effects; or, would impair an individual s ability to safely escape from a dangerous atmosphere. IDLH atmospheres are: All oxygen deficient atmospheres, Atmospheres with unknown contaminants or concentrations, Atmospheres that meet or exceed established IDLH levels. Approved Respiratory Protective Equipment Respiratory protective equipment that has been proven to provide adequate protection against the particular hazard for which it was designed and is NIOSH approved. NIOSH - National Institute of Occupational Safety and Health Respirator NIOSH was created by the Occupational Safety and Health Act of 1970. NIOSH is part of the Centers for Disease Control and Prevention (CDC) in the Department of Health and Human Services. NIOSH is an agency established to help assure safe and healthful working conditions by providing research, information, education, and training in the field of occupational safety and health. A device designed to protect its wearer from the inhalation of harmful atmospheres. Supplied Air Respirator A respirator that protects the wearer from atmospheric contaminants by supplying the wearer with a clean breathing atmosphere. Supplied air respirators do not filter contaminated air. They deliver a clean, respirable air supply to the wearer. Examples include a Self-Contained Breathing Apparatus (SCBA), an airline
respirator (fresh air unit), a NIOSH approved helmet or hood, or an escape pack (Ska-Pak). Air Purifying Respirator A respirator that protects the wearer from atmospheric contaminants by physically filtering the air through an absorbing media. Air purifying respirators include disposable dust respirators, half-mask and full face chemical cartridge/canister respirators. Canister/Cartridge Service Life The period of time a canister/cartridge will effectively adsorb the contaminants it is designed to adsorb. If provided with an end-of-service-life-indicator the unit will show when the adsorbent is no longer effective. If there is no end-of-service-lifeindicator, then the canister/cartridge life must be calculated according to the manufacturer s instructions. End-of-Service-Life-Indicator (ESLI) A system that warns the respirator user of the approach of the end of adequate respiratory protection, for example, that the sorbent is approaching saturation or is no longer effective. Odor Threshold Limit The lowest concentration of a contaminant in air that can be detected by smell. Permissible Exposure Limit (PEL) An occupational exposure limit published and enforced by OSHA as a legal standard. A PEL is usually shown as parts per million (ppm) or milligrams per cubic meter (mg/m3) of a chemical gas, vapor, or particulate in air. Threshold Limit Value (TLV) Exposure level guidelines established by the ACGIH (American Conference of Governmental Industrial Hygienists), which are usually equal to or more conservative (lower) than the OSHA PELs. Time Weighted Average (TWA) The airborne concentration of a contaminant to which a person is exposed, averaged over the total exposure time, generally the total workday (8 to 12 hours). Short Term Exposure Limit (STEL) An OSHA allowed short-term exposure limit that allows for brief exposures (15 30 minutes) above the PEL. Ceiling Limit An airborne concentration of a toxic substance that can never be exceeded.
Monitoring Exposure monitoring, through the use of personal monitoring devices, area monitoring devices, and direct reading instrumentation, that is designed to evaluate and document unit compliance with applicable exposure limits. Analytes monitored for will be determined by the unit s exposure assessment. Exposure Assessment An assessment to identify and evaluate all potential chemical hazards in the work place. The objective of the assessment is to document exposure conditions for all work tasks through monitoring. Clean Shaven Free from facial hair that comes between the sealing surface of a respirator face piece and the wearer s skin or that interferes with the wearer s face-to-face piece seal or the operation of the inhalation/exhalation valve. Attachment 13.14.01 Facial Hair Reference shows the sealing surface of a respirator mask and acceptable and unacceptable facial hair. Assigned Protection Factor (APF) The workplace level of respiratory protection that a respirator is expected to provide to employees when a continuing, effective respiratory protection program is implemented. 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. The MUC can be determined by multiplying the assigned protection factor (APF) by the OSHA permissible exposure limit (PEL), short-term exposure limit, or ceiling limit. When no OSHA exposure limit is available for a hazardous substance, the MUC must be determined based on relevant available information and professional judgment. Program Administrator Person who is qualified by appropriate training or experience that is commensurate with the complexity of the program to administer or oversee the respiratory protection program and conduct the required evaluations of program effectiveness. PPE Grid Matrix A spreadsheet in matrix form that can be used to select personal protective equipment for every task and area/department. PPE matrices can be accessed on Documentum. The matrix is also available in hard copy form and may be posted in all manufacturing areas.
4. RESPONSIBILITY 4.1 Facility Management i. Ensure that an Exposure Assessment for their unit/department is performed. i Ensure Personal Protective Equipment Grid Matrices are developed and requirements are followed. Engineering controls are used where feasible. Ensure that only NIOSH approved equipment is purchased and issued, and provide necessary accessories, as needed, i.e., spectacle kits, communications systems, etc. for BASF employees. v. Ensure that individuals that voluntarily use (not required by unit/department) respiratory equipment are provided with a copy of Attachment 13.14.05 to this procedure. vi. v vi ix. Ensure that where required a canister/cartridge change out schedule is developed and implemented. Ensure that medical evaluations for all personnel that are required to wear respirators are performed annually and that the required documentation is received from the Medical Department. Ensure that all personnel that are required to wear respirators are fit-tested annually for all of the respirator types they are required, or may be required, to wear. Ensure that an inspection, cleaning, disinfecting, storage, maintenance and repair program is developed, implemented and maintained. Note: Repairs shall only be performed by qualified personnel; using only NIOSH approved manufacturers parts. x. Ensure that training requirements for all respirator users are met and that verification of training is documented. xi. x Audit respirator program periodically for compliance. Communicate changes in the work environment to EHS personnel and ensure, as needed, that when incidents/events warrant such, specific area monitoring for potential elevated levels of regulated contaminants is performed and that any necessary precautions or corrective measures are instituted.
4.2 EHS Department i. Ensure that the contents of this site procedure, its attachments and related work instructions, are maintained in current status. i Designate, in writing, the site s Respiratory Protection Program Administrator. Approve the type or respiratory protection equipment purchased. Perform breathing air quality checks, as required/needed. v. The site nurse will perform fit tests according to Attachment 13.14.03. vi. Evaluate the training program and employee s understanding of the requirements annually using Attachment 13.14.04. 4.3 Program Administrator i. Administer and oversee the site s Respiratory Protection Program and conduct the required evaluations of the program s effectiveness. The Central HUB EHS Safety Specialist (Brandon Walker) will be the site Program Administrator for this procedure. 4.3 EHS Safety Specialist i. Conduct monitoring in accordance with each unit s exposure assessment i Recommend monitoring methods as necessary for incident/event specific monitoring. Review and recommend updates to this procedure as necessary. 4.5 Employees Required to Wear a Respirator i. Assist in the unit/department s exposure assessment. i Assist in the unit/department s development of the PPE Grid Matrix with emphasis on respiratory requirements. Adhere to the facial hair reference as outlined in Attachment 13.14.01 at ALL times. Undergo required medical evaluation before using respirators. v. Undergo required fit testing for respirator types to be used. vi. v vi Use only approved respirators and cartridges in areas where respirators are required. Inspect the respirator before each use. Perform a user seal check to ensure that an adequate seal is achieved each time the respirator is put on.
ix. Clean respirators after each use and store in a sealable bag in a clean, dry location. 4.6 Contractors i. Contractor companies whose employees wear respiratory protective equipment are responsible for the following: a) Development and implementation of a company specific respiratory protection program that satisfies the requirements of 29 CFR 1910.134, or 29 CFR 1926.103. b) Provide its employees with any respiratory equipment necessary to perform assigned tasks. c) Follow the area specific PPE Grid Matrix requirements for the unit/department they are working in. 5. PROCEDURE d) Contract companies may substitute equivalent NIOSH approved respiratory protective equipment. 5.1 Medical Evaluations i. The site s Medical Department will provide a medical evaluation as outlined in BC009.11 for each employee who uses a respirator. The purpose of the evaluation is to determine the employee s ability to safely wear a respirator while working. i The medical evaluation must be performed before the employee is fit tested or required to wear the respirator in the workplace. Upon completion of the medical evaluation the medical department forwards a written copy of the evaluation to the employee s supervisors regarding any limitations or restrictions using a respirator. Additional medical evaluations will be provided whenever there are any indications that a re-evaluation is appropriate, which includes: a) An employee reports or experiences medical signs or symptoms that are related to the ability to wear a respirator. 1. Weight loss or gain 2. Facial scarring around the facepiece seal 3. Medical procedures (cosmetic or dental) b) Site medical, a manager, or the site s Respiratory Program Administrator informs site management that the employee needs to be re-evaluated. c) A periodic audit indicates the need for employee re-evaluation. d) A change in the work place conditions results in a substantial increase in the employee s physiological burden. e) A new respirator is needed to perform the work.
5.2 Facial Hair Policy f) There is a change in the minimum frequency requirements in BC009.011. i. All BASF Kankakee employees and contractor employees whose jobs may require the use of respirators (to perform manual job duties or respond to emergencies) must be clean-shaven. i The need for respirators will documented on the PPE matrix. Non-nested contractors and visitors, including truck drivers and vendors, will not be required to be clean-shaven. However, should they be involved in work activities requiring a respirator they must be clean-shaven. Personnel who are required to be clean-shaven must come to work shaven. Note: The desire to wear facial hair will not be an acceptable excuse for not performing a given task or for not working in a given area of the plant site. v. See Attachment 13.14.01 of this procedure for examples of cleanshaven. 5.3 Hazards Assessment i. Respiratory hazards will be identified via the exposure assessment process which incorporates Industrial Hygiene monitoring to quantify the potential exposure to respiratory hazards. Additionally, the EHS Safety Specialist will make a quantitative assessment of the tasks that may expose employees to a respiratory hazard. i Finally, in addition to the quantitative assessment the EHS Safety Specialist will incorporate input from personnel performing tasks that may expose them to respiratory hazards via interviews. Based upon this exposure assessment process the need to use respiratory protection is documented in the unit s PPE matrix.
5.4 Respirator Selection i. Attachment 13.14.02 APRs and Air Purifying Respirators contains additional guidelines for proper respirator selection. The purpose of this attachment is to ensure that respirators with the proper assigned protection factors (APFs) are selected, and that respirator maximum use concentrations (MUCs) are not exceeded. i Respirator selection must be based on hazards identified by exposure monitoring, and should address applicable established exposure limits, (i.e., PEL s, TLV s, etc.) The work activity and practicality of the respirator for the task, as well as, respirator characteristics (half-mask vs. full-mask, etc.) must be considered. 5.5 Respirator Use IDLH atmospheres I. Only the following shall be used in IDLH atmospheres: a) A full face-piece pressure demand SCBA certified by NIOSH for a minimum service life of thirty minutes, or b) A combination full face-piece pressure demand supplied air respirator (SAR) with mandatory auxiliary self-contained air supply (Ska-Pak). Recommendation: 1 hour SCBA may be better suited for emergency response purposes due to increased amount of time that may be required. Note: All oxygen-deficient atmospheres shall be considered IDLH.
Non-IDLH atmospheres i. Use a respirator appropriate for the chemical state and physical form of the contaminant. i Gases and vapors Use an atmosphere-supplying respirator (SCBA/SAR), or, an air purifying respirator, provided that: The respirator is equipped with an end-of-service-life indicator (ESLI) certified by NIOSH for the contaminant; or If there is no ESLI appropriate for conditions in the workplace the unit/department must have in place a change schedule for canisters and cartridges that assures that they are changed out before the end of their service life. Particulates Use an atmosphere-supplying respirator (SCBA/SAR) or an air purifying respirator equipped with a filter certified by NIOSH under 30CFR Part II as a high efficiency particulate air (HEPA) filter, or an airpurifying respirator equipped with a filter certified for particulates by NIOSH under 42 CFR Part 84. v. Air purifying respirators shall not be used in the following conditions: a) IDLH atmospheres b) If canisters/cartridges have an expired shelf life date c) If the canister/cartridge has no ESLI or a canister/cartridge changeout schedule has not been established d) Fire fighting Non-IDLH atmosphere-voluntary use Employees who choose to wear respirators when such use is not required by the unit/department shall be provided with a copy of Attachment 13.14.05 of this procedure. Voluntary use of respirators other than nonmandatory dust masks requires that all medical clearance and training requirements be met.
5.6 Canisters/Cartridges Identification i. Air purifying respirator canister/cartridge identification is standardized per 29 CFR 1910.134. The primary means for identifying a canister/cartridge is through a worded label. The secondary means is through color-coding. The label shall not be removed and must remain legible. The Kankakee facility uses the following cartridges: Contaminant to be protected against Organic Vapor, Ammonia, Methylamine, Formaldehyde and Acid Gas (Chlorine, Hydrogen Chloride, Sulfur Dioxide, Hydrogen Sulfide [Escape], Hydrogen Fluoride, Chlorine Dioxide) with a P100 particulate filter (99.97% minimum filter efficiency) for all particulates Organic Vapor, Ammonia, Methylamine, Formaldehyde and Acid Gas (Chlorine, Hydrogen Chloride, Sulfur Dioxide, Hydrogen Sulfide [Escape], Hydrogen Fluoride, and Chlorine Dioxide Organic vapors P100 Particulate Filter (99.97% minimum filter efficiency) for all particulates Cartridge Color and Part Number Olive and Magenta North 75SCP100 Defender Cartridge with P100 HEPA Olive North 75SC Defender Cartridges Black North N75001 Magenta North 7580P100 and 75FFP100 Cartridges Service Life/Change Schedule i. None of these cartridges for vapor protection has an ESLI indicator. All cartridges used for vapor protection must be changed at the end of the shift. i Service life determinations for non-esli equipped canisters/cartridges can be determined by reviewing the manufacturer s data, determination of expected exposure concentrations and from monitoring data. Documentation of the information and data relied upon, the basis for the canister/cartridge change schedule, and the basis for reliance on the data shall be kept by the unit/department as part of their assessment.
5.7 Fit Testing i. Before an employee may be required to use any respirator with a negative or positive pressure tight fitting face piece, the employee must be fit tested with the same make, model, style, and size of respirator that will be used. i Employees shall be fit tested prior to initial use of the respirator; whenever a different respirator face piece (size, style, model or make) is used; and at least annually thereafter Positive pressure supplied air respirators must be fit tested in the negative mode. If disposable dust respirators (i.e. 3M nose/mouth filters) are required then fit testing shall be performed. If they are not required but are used voluntarily, then fit testing is not required. v. Fit testing must be repeated when an employee indicates that a previously fitted respirator is unacceptable. The employee must be given the opportunity to choose other respirators and then be re-tested. vi. v vi Fit testing must be repeated whenever the employee reports (or the medical department, manager or program administrator makes visual observations of) changes in the employee s physical condition that could affect respirator fit. Such conditions include, but are not limited to, facial scarring, dental changes, cosmetics surgery, or an obvious change in body weight. Fit testing will be quantitative using a Portacount condensation nuclei counter as outlined in Attachment 13.14.03 Fit Testing Procedure. Fit testing results must be documented and the current year s record must be retained in the employee s training file. 5.8 Breathing Air i. Plant air (instrument or utility) must not be used for breathing air purposes. Breathing air for all supplied air systems shall at least meet the compressed gas association (CGA) commodity specification for Grade D type 1 air. Grade D Breathing Air Requirements Limiting Characteristic Allowable Limits Percent Oxygen (O 2 ) 19.5 23.5% Carbon Monoxide (CO) 10 ppm Carbon Dioxide (CO 2 ) 1000 ppm Water No liquid present Oil (condensed) 5 mg/m 3 Odor No pronounced odor i Breathing air cylinder and bottle labels must indicate that its contents satisfy the Grade D specification and must include the following statement, according to the NIOSH respirator certification standard 42 CFR, part 84.81.
5.9 Oxygen Check Procedure i. Install an approved pressure regulator onto the cylinders supply valve assembly. i Hook up the respirator (and hose) Using an approved and calibrated oxygen analyzer place the analyzers hose in close proximity to the air inlet on the respirator. Open the cylinder valve slowly and after a few seconds of purging check the O2 content. The content should be in the 20 to 20.8% range Note: If the supply source is a multi-cylinder assembly with individual cylinder supply valves then each cylinder s O 2 content must be checked. If the oxygen content of any of the cylinders is not in the Grade D specification range it must be segregated through disconnecting or double blocked and bled. If unable to 100% isolate it from the other cylinders then the whole multi-pak must be appropriately tagged and not used. v. Document the O 2 Quality Check by initialing the In Service Tag and affix onto the cylinder supply valve. Note: Spare cylinders can be checked in a similar way and tagged if OK. Once the initial testing is performed and documented (tagged) subsequent usage does not require testing. 5.10 Storage and Accessibility i. All face pieces for supplied air and air purifying respirators shall be stored in sealed plastic bags (e.g., Ziploc-type bags). Used cartridges and filters for air purifying respirators shall never be stored in the same bag as the respirators. Cartridges and filters shall be removed and discarded or stored in a separate plastic bag, as required by the unit/department s PPE requirements list (grid). All respirators shall be stored to protect them from damage, contamination, dust, sunlight, extreme temperatures, excessive moisture, and damaging chemicals, and they shall be packed or stored to prevent deformation of the face piece and exhalation valve.
5.11 Training i. All employees whose job assignment requires, or may require, the use of respiratory equipment must be trained in the selection, use, limitations and care of respiratory equipment. i The training shall be conducted upon initial unit/department assignment and annually, as a minimum, thereafter. Re-training shall be done when changes to the requirements are made, new type equipment is introduced or when deficiencies to the program are noted. The training must include the following: a) A review of the unit/ppe Grid Matrix with emphasis on the task specific respirator required section of the table. Note: The requirements for stand-by/back-up personnel should be emphasized. b) The actual handling and wearing of each of the types of respirators to be used by the employee for an appropriate familiarization period. c) The proper fitting and adjustment of all respirator types to be used by the employee. d) The proper method for performing a positive and negative pressure check of the respirator(s) prior to each use. e) The conditions that may compromise the integrity of the face-to-face-piece seal i.e. facial hair, hard hats, eyeglasses, facial features, etc. f) Fit testing of all tight fitting face-piece respirators to be used by the employee. g) How to use the respirator effectively in emergency situations, including situations in which the respirator malfunctions. h) De-contamination procedures, if needed, prior to removing the respirator. i) The site policy on the use of corrective lenses (eye glasses and contact lenses). j) Approved accessories, i.e., communications systems, respirator spectacle kits (corrective lenses). k) The contents of this procedure and its attachments. l) In addition to the training listed above, unit/department supervision and all employees with designated responsibility for developing the PPE Grid Matrix and those who issue respirators must attend training that includes additional information pertaining to the selection, use and limitations of the various types of respiratory protection equipment. HAZWOPER training can be used to satisfy this requirement.
5.12 Recordkeeping i. Written records regarding medical evaluations and fit testing are required. This information will facilitate employee involvement in the respirator program, assist in auditing the adequacy of the program and provide a record for compliance determinations. a) Medical Evaluations Records shall be retained as per the requirements of BC009.001 Retention and Release of Medical Information/Records. b) Fit Testing A record of the quantitative fit test administered must be retained. The record shall include: 1. The name or identification of the employee tested; and size of the respirator(s) tested 2. Specific make, model, style, and size of the respirator(s) tested 3. Date of test; and 4. The fit factor and strip chart recording or other recording of the test results for quantitative fit testing. c) Fit test records shall be retained for respirator users until the next fit test is administered. d) Respirator Program Written records of the current respirator program e) Purchased breathing air Certificate of Analysis. f) Breathing air quality check RELATED DOCUMENTS BC009.011 - Respirator Clearance Procedure Health Professionals 29 CFR 1910.134 - Respiratory Protection 29 CFR 1926.103 Respiratory Protection
6.0 ATTACHMENTS Attachment 13.14.01 - Respirator Face Piece Sealing Surface and Acceptable and Unacceptable Facial Hair for Respirator Wearers Attachment 13.14.02 Assigned Respiratory Protection Factors (APRs) and Air Purifying Respirators Attachment 13.14.03 Fit Testing Procedure Attachment 13.14.04 Respiratory Protection Training Attachment 13.14.05 - Information for Employees Using Respirators When Not Required Under the Standard (Mandatory) PROCEDURE HISTORY Rev. No.: Reason: Initiator: Date: 0 Consolidation of Procedures for BASF NA EHS Council 02/01/01 1 Revise Section 5.3 EHS Council 07/03/01 2 Revised Sections 5.2 and 5.4 Steve Hull 05/06/04 3 Periodic review Steve Hull 06/18/07 4 Reissue and removed attachments from the Steve Hull 09/03/10 body of the procedure. Future revision history will be maintained in Domino.doc. 5 Revised to include change out requirement for Steve Hull 8/24/12 the end of shift. 6 Major revision to include the requirements Steve Hull 9/24/12 listed in BASF Respiratory Protection Compliance Guidelines. 7 Periodic review James Emch 7/10/16