Yanbu National Petrochemical Company Site Safety Procedures Manual
Yanbu Petrochemical Complex U & O Project July 2005
Fluor Arabia Limited Contract A2IT Page 1 of 11
24. RESPIRATORY PROTECTION PROGRAM
A. GENERAL
This program sets forth accepted practices for respirator use to protect employees against the
inhalation of harmful air contaminants and oxygen-deficient atmospheres in the workplace
where required by regulations and/or specified by the Owner’s Safety Department.
The purpose of this program is to provide information and guidance to Contractors as to proper
selection, use, fitting, cleaning, storing, inspection, documentation, and administration of an
acceptable respirator protection program that will help safeguard the health and life of the users.
This program is intended to control occupational diseases caused by breathing air contaminated
with harmful dust, fogs, fumes, mists, gases, smokes, sprays, or vapors. The primary objective
will be accomplished as far as feasible by accepted engineering control measures. For example,
enclosure or confinement of the operation, general and local ventilation and substitution of less
toxic material. When effective engineering controls are not feasible, or while they are being
instituted, appropriate respirators will be used.
The requirements of this procedure will be provided at no expense to the employee.
References:
1) Occupational Safety and Health Standards for the Construction
Industry 29 CFR Part 1926 with amendments effective April 8, 1998, including 29 CFR
Part 1910 General Industry Standards Applicable to Construction.
2) American National Standard: Practices for Respiratory Protection -
ANSI-Z88.21980.
B. DEFINITIONS
1) Air-purifying respirator: A respirator with an air-purifying filter, cartridge, or canister
that removes specific air contaminants by passing ambient air through the air-purifying
element.
2) Atmosphere-supplying respirator: A respirator that supplies the respirator user with
breathing air from a source independent of the ambient atmosphere, and includes
Supplied-Air Respirators (SARs) and Self-Contained Breathing Apparatus (SCBA)
units.
3) Confined Space: An enclosure such as a storage tank, process vessel, boiler (if
designated), silo, tank car, pipeline, tube, duct, sewer, underground utility vault, tunnel,
or pit having limited means of egress and poor natural ventilation and which may
contain hazardous contaminants or be oxygen deficient. This includes permit required
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and non-permit required confined spaces.
4) End-of-service-life indicator (ESLI): A system that warns the respirator user of the
approach of the end of adequate respiratory protection.
5) Escape-only respirator: A respirator intended to be used only for emergency exit.
6) Exhalation Valve: A device that allows exhaled air to leave a respirator and prevent
outside air from entering through the valve.
7) Filter or air-purifying element: A component used in respirators to remove solid or
liquid aerosols from the inspired air.
8) Filtering facepiece (dust mask): A negative pressure particulate respirator with a filter
an integral part of the facepiece or with the entire facepiece composed of the filtering
medium.
9) Fit factor: A quantitative estimate of the fit of a particular respirator to a specific
individual, and typically estimates the ratio of the concentration of a substance in
ambient air to its concentration inside the respirator when worn.
10) High efficiency particulate air (HEPA): A filter that is at least 99.97% efficient in
removing monodisperse particles of 0.3 micrometers in diameter. The equivalent
NIOSH 42 CFR 84 particulate filters are the N100, R100 and P100 filters.
11) Hood: That portion of respirator, which completely covers the head, neck and portions
of the shoulders.
12) Immediately dangerous to life or 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 escape from a dangerous atmosphere.
13) Inhalation Valve: A device that allows respirable air to enter a respirator and prevents
exhaled air from leaving the respirator through the valve.
14) Irrespirable: Unfit for breathing.
15) Negative pressure respirator (tight fitting): A respirator in which the air pressure
inside the facepiece is negative during inhalation with respect to the ambient air
pressure outside the respirator.
16) Oxygen-deficient atmosphere: An atmosphere with an oxygen content of less than
19.5% by volume at altitudes of 800 feet or below.
17) Particulate Matter: A suspension of fine solid or liquid particles in air, such as dust,
fog, fumes, mist, smoke, or spray.
18) Physician or other licensed health care professional (PLHCP): An individual whose
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Yanbu Petrochemical Complex U & O Project July 2005
Fluor Arabia Limited Contract A2IT Page 3 of 11
legally permitted scope of practice (i.e., license, registration, or certification) allows
him or her to independently provide, or be delegated the responsibility to provide, some
or all of the health care services required by the medical evaluation requirements of the
respiratory program.
19) Positive pressure respirator: A respirator in which the pressure inside the respiratory
inlet covering is positive with respect to ambient air pressure outside the respirator.
20) Powered air-purifying respirator: An air purifying respirator that uses a blower to
force the ambient air through air-purifying elements to the inlet covering.
21) Pressure demand respirator: A positive pressure atmosphere-supplying respirator that
admits breathing air to the facepiece when the positive pressure is reduced inside the
facepiece by inhalation.
22) Qualitative fit test (QLFT): A pass/fail fit test to assess the adequacy of respirator fit
that relies on the individual's response to the test agent.
23) Quantitative fit test (QNFT): An assessment of the adequacy of respirator fit by
numerically measuring the amount of leakage into the respirator.
24) Routine Respirator Use: Wearing a respirator as a normal procedure when carrying
out a regular and frequently repeated task.
25) Service Life: The period of time that a respirator provides adequate protection to the
wearer. For example, the period of time that an air-purifying device is effective for
removing a harmful substance from inspired air.
26) Supplied-air respirator (SAR) or airline respirator: An atmosphere-supplying
respirator for which the source of breathing air is not designed to be carried by the user.
27) Tight-fitting facepiece: A respiratory inlet covering that forms a complete seal with the
face.
28) User seal check: An action conducted by the respirator user to determine if the
respirator is properly seated to the face.
C. MEDICAL EVALUATION
This standard establishes the guidelines for evaluating a project employee's ability to use a
respirator while working. The employee must be medically evaluated before he or she may be
fitted or use a respirator. Medical evaluations will no longer be needed if the employee is no
longer required to use a respirator for work.
1) Procedure
The medical evaluation will be performed by a physician or other licensed health care
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professional (PLHCP) utilizing a medical questionnaire or examination. The medical
questionnaire may be found in Attachment A.
2) Follow-up medical examination
The employee will receive a follow-up examination before being allowed to use
respiratory equipment if deemed necessary by the PLHCP. The follow-up examination
will include whatever tests the PLHCP requires to determine the employee may
participate in respirator use.
3) Administration of the medical questionnaire and examination
The medical evaluation will be private and will be done conveniently for the employee.
The employee must understand its content. The employee has the right to discuss the
results of the medical examination with the PLHCP.
4) Supplemental information for the PLHCP
Before the PLHCP can make a recommendation regarding respirator use by an
employee, the PLHCP requires specific information. Supplemental Information for the
PLHCP will be completed by the Site Safety Manager or designee and delivered to the
PLHCP for each employee evaluated.
The PLHCP will be given a copy of the respiratory protection program and 29 CFR
1910.134
5) Medical determination
The PLHCP will determine the employee's medical ability to use a respirator and
provide the Site Safety Manager and the employee with a completed Physician's
Recommendation Concerning Respirator Use. The recommendation contains the
following information:
ability or inability to use a respirator;
limitations on respirator use;
possible need for further evaluation or follow-up; and
statement ensuring employee has been given a copy of the recommendation.
D. REQUIREMENTS
1) The Site Safety Manager or designee will be designated the Respirator Program
Administrator. He will receive training to effectively monitor the routine use of
respirators and to know when to ask for additional support. The Respirator Program
Administrator will assist management in implementing the following program.
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a) Procedures will be developed at each project site for the selection and
use of respirators that specify which respirator to use under what conditions.
b) Procedures will be developed for medical evaluation of each employee
required to use respiratory equipment.
c) Contractor employees will be trained initially, annually, and on an as-
needed basis in the proper use and limitations of the respirators to be used for
routine or emergency work. Training will include the selection of a properly
fitting face piece and the trial wearing of each type of respirator to be used.
d) Procedures will be developed for fit testing of tight fitting respirators
for each employee required to use respiratory equipment.
e) Procedures and schedules for cleaning, disinfecting, storing, inspecting,
repairing, discarding, and otherwise maintaining respirators will be developed.
f) Procedures will be developed for ensuring adequate air quality,
quantity, and flow of breathing air for atmosphere supplying respirators.
g) The Project Safety Manager is responsible for maintaining all records i.e.,
training, fit testing, medical and surveillance associated with the program. The
effectiveness of the respirator program will be reviewed by the Project Safety
Manager at least annually. A copy of the written program and records of
training, surveillance, and annual review will be forwarded to the exposure
records file, Owner Safety Office.
2) The types of respirator equipment covered by this program are as follows:
filtering facepiece respirators;
half-mask air purifying (cartridge-type) respirators;
full-face air purifying (cartridge type) respirators;
full-face respirator with air-line or breathing air tank; and
self-contained breathing apparatus with supplied air tank for rescue respirator use.
3) Each employee engaged in a work operation which utilizes asbestos or silica
(sandblasting) will be required to meet physical examination requirements stated in the
Fluor Daniel Accident Prevention Standards manual.
4) Each employee who is subject to wear a respirator device due to the nature of the work
assignment will be evaluated to determine medical ability to use respiratory equipment.
E. EMPLOYER RESPONSIBILITY
1) The Project Safety Manager will evaluate the working environment, determine what
respirators the employees require, and make provisions for the types respirators
required.
2) A variety of respirators in a wide selection of sizes will be provided to ensure that every
employee who must use a respirator has one that fits properly.
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3) Employees will be trained on the chemicals and extent of the hazards with which they
will be working.
F. EMPLOYEE RESPONSIBILITY
1) The employee will use the provided respiratory protection in accordance with
instructions and training received.
2) The employee will report any malfunction of the respirator to the supervisor or to the
Safety Department.
3) The employee will report any change in physical condition, which could affect
respirator fit to the supervisor or to the safety department.
4) The employee will report any medical signs or symptoms related to the ability to use
the respirator to the supervisor or the safety department.
5) The employee will report to the supervisor or the safety department if the fit of the
respirator becomes unacceptable.
6) Employees are responsible for these respirators while in their possession. This means
properly storing the respirator while not in use in the work area.
G. PROGRAM ADMINISTRATION
1) The Site Safety Manager will administer the respirator program. Responsibility and
authority for the respirator stocking, cleaning, fitting, maintenance, and issuance is
assigned to the Site Safety Manager or designee.
2) All fit testing will be conducted at the site office or other suitable facility.
3) Respirator room personnel will maintain a list of employees who have fit tested for
respirators. The type and size of respirator will be listed. Only approved employees will
be able to check out respirators from the tool room.
H. PROCEDURE
1) Training: Each respirator wearer will be given documented training, which will include
explanations and discussion of:
the respiratory hazard and results of improper fit, use, maintenance, or malfunction;
the engineering and administration controls being used and the need for respirators
to provide protection;
the reason for selecting a particular type of respirator;
the function, capabilities, and limitations of the selected respirator;
the operation;
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the proper wearing of the respirator;
respirator inspection, cleaning, storing, and maintenance;
how to recognize medical signs and symptoms that may limit or prevent the
effective use of respirators;
the general requirements of the respiratory protection program; and
Recognizing and handling emergency situations.
2) Respirator Fitting: Each respirator wearer will be provided with a respirator fitted in a
qualitative or quantitative manner. A fitting test will be used to determine the ability of
each individual respirator wearer to obtain a satisfactory fit with a negative-pressure
respirator. The results of qualitative or quantitative respirator fitting tests will be used to
select specific types, makes, and models of negative-pressure respirators.
Each respirator wearer will be provided with a fitted respirator and receive fitting
instructions, including demonstrations and practice in how the respirator should be
worn. How to adjust it, and how to determine if it fits properly. Refer to Respirator Fit
Testing Record.
Each respirator wearer will be required to check the seal of the respirator by appropriate
means prior to entering a harmful atmosphere. Respirators will not be worn when
conditions prevent a good face seal. Conditions, such as growth of facial beards where
hair comes between the sealing periphery of the face piece and the respirator, will be
removed before fitting or wearing a respirator.
The wearer of a respirator equipped with a full face piece, helmet, hood, or suit will not
be allowed to wear contact lenses. If a spectacle, goggle, face shield, or welding helmet
must be worn with a face piece, it will be worn so as not to adversely affect the seal of
the face piece to the face.
3) Selection and Issuance of Respirator: The proper type of respirator for each
respiratory hazard will be determined at the time the respirator is issued. Only persons
trained to ensure that proper fitting and proper types of respirators are issued will be
permitted to issue respirators to persons needing them.
4) Respirator Cleaning, Storage and Inspection: The respirator room attendant will be
responsible for ensuring all respirators are cleaned, stored, and inspected properly.
Respirators that are used routinely will be inspected before every use (by the wearer)
and when the equipment is being cleaned (by the attendant). Emergency use respirators
will be inspected in compliance with the manufacturers' criteria at least once per month.
Emergency Respiratory Protection Monthly Inspection Report, will be used for
recording respirator inspections.
In addition, emergency equipment will be inspected for proper function before each use
and after use while being cleaned. If escape-only respiratory protection is kept on site, it
will be inspected before it is brought into the work area.
I. MONITORING RESPIRATOR USE
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1) The Site Safety Manager will monitor all respirator inspections and the use of
respirators to ensure that they are worn properly.
2) The Area Manager will monitor his or her areas to ensure that employees working
under his or her supervision are in compliance with the program.
3) Supervisors (General Foremen and Foremen) will assure that employees working under
their supervision are in compliance with the respiratory protection program and will
notify the Site Safety Manager involving any doubts about the selection, use, and
maintenance of respirators. Supervisors are responsible for ensuring that employees are
properly instructed on how to wash, change cartridges or make adjustments to
equipment if they detect break through or resistance. In addition, supervisors will assure
that respirators are turned in daily for proper cleaning and disinfecting.
4) The individual responsible for issuing respiratory equipment will be adequately
instructed to ensure that the correct respirator having the proper fit is issued. All
respirators assigned to employees will be identified by the employee's social security
number and size of the respirator. It is the tool room attendant's responsibility to ensure
that respirators are inspected before and after each use or that they be returned to a
designated location for cleaning and storage.
J. RESPONSIBLE PERSONS
1) Site Safety Manager or Designee
Identify hazards, select types of respirators based on the hazards and factors
affecting performance.
Assure that a selection of respirators and appropriate cartridges are available for use
for any respiratory hazards that may be encountered. Brands and models are listed.
Conduct training for all site employees concerning fitting, selection, application,
and limitations of respirators to be used.
Review the respirator program at least annually and assure that the requirements of
this procedure are being met.
Coordinate and perform fit testing for employees required to wear a respirator.
2) Supervisor
Recognize work areas where respiratory protection may be required and provide
appropriate equipment to safely perform assigned tasks.
Coordinate with the Site Safety Manager regarding questions that may arise
concerning respirators and their application.
3) Employee
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Inspect personally assigned respirator before each use to assure that it is free of
defects that could affect its protective capabilities.
Place the respirator in a sealed bag at the end of each shift or return it to the tool
room when work requiring a respirator is complete.
4) Respirator Room Attendant
Assure that respirators in stock are properly stored, sealed, and categorized by size.
Pending sanitation for re-use, respirators will be placed in a bin or other storage
area labeled "Do Not Use".
Cleaning and disinfecting of respirators will be accomplished in accordance with
site specific procedures and methods that comply with established procedures at
each project.
K. CARTRIDGE SELECTION
Graphic posters which display cartridge selection for specific hazards will be displayed at or
near the location where respirators are stored.
A cartridge change schedule will be developed at each site using cartridge manufacturer's data
to ensure cartridges are changed before reaching end of service life. This applies to cartridges
without ESLI indicators. This will also be posted where respirators are stored.
L. IDLH ATMOSPHERES
Only certain types of respirators are allowable in IDLH atmospheres. They include the
following:
1) an SCBA, full facepiece with minimum service life of 30 minutes;
2) a combination supplied air respirator with an auxiliary self-contained supply; and
3) a respirator specifically certified by NIOSH for escape from an IDLH atmosphere.
Note: All respirators will be NIOSH certified.
When employees must enter IDLH atmospheres, project management will be notified. A
specific IDLH entry plan will be created in which one or more rescue personnel will be located
outside the IDLH area and will maintain contact with the employees in the IDLH area. The
rescue personnel outside the area will be trained to provide effective emergency rescue and will
be equipped with retrieval equipment or other means for rescue as necessary.
M. PROGRAM EVALUATION
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The Site Safety Manager will evaluate the respiratory protection program as necessary to ensure
it has been implemented and is effective. The Site Safety Manager or designee will regularly
consult employees to determine their views on what changes may need to be made to the
program. Factors which may be assessed include the following:
Respirator fit
Respirator selection for various hazards
Proper use of the respirators
Proper respirator maintenance
N. VOLUNTARY USE OF RESPIRATORS
In areas where respirators are not required by the respiratory protection program, filtering
facepiece (dust masks), may be provided if requested by the employee. The following
conditions must be met:
a) Only NIOSH/MSHA-approved filtering facepieces will be used.
b) All filtering facepieces will be worn in compliance with manufacturer's guidelines and
all federal and state regulations.
c) Filtering facepieces will not be issued if they create a hazard.
Note: If during the scope of an employee's work, it is deemed necessary that a
respirator is needed to perform certain job functions, the employee will need to
meet all of the requirements to wear a respirator.
O. BREATHING AIR QUALITY
1.) Air supplied to air line respirators or self contained breathing apparatus shall meet the
requirements for Grade D breathing air as a minimum.
• Oxygen: 19.5% min., 23.5% max.
• Carbon Dioxide: 0.1% max.
• Carbon Monoxide: 10 ppm max.
• Condensed Hydrocarbons: 5 mg/m3 max.
• Water: Concentration to be below the dew point when the air is released into face
piece.
2.) Breathing air cylinders must meet DOT requirements.
3.) Oxygen is not to be used as breathing air.
4.) An air compressor system may be used to supply breathable air provided the
compressor does not require oil to lubricate the piston rings and valves and the
compressor:
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is located away from air contaminants;
• a filter to remove oil mist;
• charcoal to remove oil vapor;
equipped with an in-line purification system that has been inspected and tagged to
indicate date of change out;
a carbon monoxide monitor is in place and set to alarm at 10 PPM; and
respiratory hose fittings are incompatible for non-respirable gases and containers.
an air tank with sufficient capacity to allow the respirator user to escape to clean air
upon compressor failure.
a compressor failure alarm capable of warning the respirator user or his standby; and
a compressor air intake located away from air contaminants such as engine exhaust,
ventilation exhaust, process vents, welding fumes, or paints spray.
5.) Airline respirator couplings shall be incompatible with all other couplings.
6.) When air is supplied from cylinders, the quantity of air available shall be monitored
frequently enough to ensure that the airline respirator user will leave the contaminated
atmosphere before the air supply runs out.
ATTACHMENTS
ATTACHMENT A: MEDICAL EVALUATION QUESTIONNAIRE
ATTACHMENT B: SUPPLEMENTAL INFORMATION GUIDE
ATTACHMENT C: PHYSICIAN'S RECOMMENDATION CONCERNING RESPIRATOR USE
ATTACHMENT D: RESPIRATOR FIT TESTING RECORD
ATTACHMENT E: EMERGENCY RESPIRATORY PROTECTION MONTHLY INSPECTION
REPORT
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