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DOC.
SAFETY
DIVISION STEEL WORKS EFF. DATE 31.05.2005
STANDARD
SS/
DOC. # TITLE Respiratory protection REVISION 00
PROCESS-01
DUE FOR
SHEET 1 OF 9 01.06.2008
REVISION
COMP. BY S BISWAS SIGNED DATE 20.05.2005

SURESH
AUTH. BY SIGNED DATE 21.05.2005
KUMAR

1.0 Purpose: To define the responsibilities and procedures for protecting all employees (of the
company as well as of the contractors) against respiratory hazards through the use of respiratory
protective equipment.
2.0 Reference:.
3.0 Associated Hazards: Suffocation, toxic gas inhalation
4.0 Applicability: Inside Tata Steel Works
5.0 Responsibility: Working departments, Contractors.
6.0 Procedure:
General
1. The primary control of contaminated air shall be maintained through engineering methods by
confining processes, providing exhausts, or providing substitution of less toxic materials. Where
engineering remedies are not feasible or are not available, or while they are being evaluated or
implemented, and when the atmospheric exposure to a toxic material may exceed the
recommended ceiling or time-weighted average limit for a given pollutant, respiratory protection
will be required to protect the health of employees.
2. Indication of danger zones will be made where the use of respiratory protective equipment is
mandatory by appropriate safety signs.
3. Appropriate respiratory protection will also be provided upon request by any employee.
4. Emergency respiratory protection should be made available to workers and their
representatives. The respiratory protection should be appropriate to the hazard and risk in
question.
5. When the hazard and risk cannot be assessed with sufficient accuracy to define the appropriate
level of respiratory protection, area manager should make positive pressure air-supplied
respiratory protective devices available.
6. Suitable respirator will be provided to the employee by the department in consultation with
Safety and Ergonomics expert and Medical agency (if required).
7. It is required that respirator wearers must be clean shaven in the area of the sealing surface of
the respirator. The sealing surface is the area where the respirator touches the face and chin.
8. If prescription glasses are required for use with a full-face respirator, a special clip and pair of
prescription glasses that do not interfere with the seal must be ordered and worn.
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DOC.
SAFETY
DIVISION STEEL WORKS EFF. DATE 31.05.2005
STANDARD
SS/
DOC. # TITLE Respiratory protection REVISION 00
PROCESS-01
DUE FOR
SHEET 2 OF 9 01.06.2008
REVISION
COMP. BY S BISWAS SIGNED DATE 20.05.2005

SURESH
AUTH. BY SIGNED DATE 21.05.2005
KUMAR

6.1 Respirator Procedure Waiver

1. The purpose of the Respirator Procedure Waiver is to allow a work area or a work group to
deviate from the established Respirator Procedure.
2. Any deviation from the Respirator Program is granted with specific limitations. Special safety
precautions may be required and must be documented. Waivers are given for up to a year and
therefore must be reviewed and re-authorized annually.
3. Use a waiver when the procedure cannot apply to a particular situation and its application will
not create a hazard. Waiver can be used when the respirator use is limited to voluntary use of
filtering face pieces (dust masks).
4. Do not use a waiver to shortcut or evade established use, procedures, which represent the
best practices for Tata Steel.
5. The waiver applies to a particular job, area, person, or circumstance; and it can be approved
for a one-time application or recurring 1-year basis.
6. The EHS co-coordinator must review any new or temporary waiver with all affected employees
and emphasize any special precautions to be taken. This review should be repeated on an
annual basis.
7. The EHS coordinator is responsible for maintaining a master file on all Respirator Waivers. The
coordinator will issue a list of waivers due for reauthorization at the beginning of each year.
8. The EHS co-coordinator must have a list of 1-year waivers readily available in the area and
initiate reauthorization during the first quarter of each year.
9. The Supervisor/Manager of the work group/work area and EHS Coordinator must sign the
request form for waiver.
10. All waivers require the approval of the Safety & Ergonomics department representative.
6.2 Assessment and selection of respiratory protective equipment
1. Before choosing respiratory protective equipment, the area manager is required to analyze and
subsequently assess the risks which are present in the working environment and which cannot
be avoided by other means than by using respiratory protective equipment.
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DOC.
SAFETY
DIVISION STEEL WORKS EFF. DATE 31.05.2005
STANDARD
SS/
DOC. # TITLE Respiratory protection REVISION 00
PROCESS-01
DUE FOR
SHEET 3 OF 9 01.06.2008
REVISION
COMP. BY S BISWAS SIGNED DATE 20.05.2005

SURESH
AUTH. BY SIGNED DATE 21.05.2005
KUMAR

2. After the risks have been identified, the need for respiratory protection shall be assessed and
the characteristics which respiratory protective equipment must have in order to be effective
against the risks shall be determined.
3. When selecting respiratory protective equipment, one shall also take into account the risks and
other influences which the equipment itself may create.
While selecting a respirator for a particular job environment following factors to be considered
Ø Severity of hazard
Ø Expected activity of the wearer
Ø Degree of protection required
Ø Ease and comfort with which it can be worn
Ø Men using the equipment should understand its operation and necessity of use.
4. The assessment shall be reviewed if any changes are made to the working environment or to
any other factors which may influence the assessment.
5. The specimen table provided for in Annex 1 may be used as a guideline upon the survey of the
risks present at the workplace.
6. A non-exhaustive guide list of items of respiratory protective equipment (available at Tata Steel)
is provided in Annex 2.
7. The area manager shall make sure that all respiratory protective equipment:
A. Fully meets the need for protection;
B. Does not require excessive physical effort on the part of the user and does not reduce the
effect of any device worn by the user to correct his or her sight or hearing;
C. Fits the wearer correctly;
D. Corresponds to existing conditions at the workplace;
E. Complies with ergonomic requirements and corresponds to the worker's state of health.
F. Where the presence of more than one risk makes it necessary for a worker to wear
simultaneously more than one item of personal protective equipment, such equipment shall be
compatible.
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DOC.
SAFETY
DIVISION STEEL WORKS EFF. DATE 31.05.2005
STANDARD
SS/
DOC. # TITLE Respiratory protection REVISION 00
PROCESS-01
DUE FOR
SHEET 4 OF 9 01.06.2008
REVISION
COMP. BY S BISWAS SIGNED DATE 20.05.2005

SURESH
AUTH. BY SIGNED DATE 21.05.2005
KUMAR

6.3 Use of Respiratory protective equipment

1. Area manager shall ensure that respiratory protective equipment is used in compliance with the
instructions supplied by the manufacturer and that it is used from the commencement of
dangerous work until the completion of the work, and shall monitor its use.
2. The conditions of use of respiratory protective equipment, in particular the period for which it is
worn, shall be determined on the basis of the seriousness of the risk, the frequency of exposure
to the risk, the characteristics of the workstation of each worker and the performance of the
respiratory protective equipment.
3. Workers are required to use respiratory protective equipment in compliance with the user
manual and the instructions provided by the area manager.
4. When organizing work, the area manager shall take into account the additional physical or
mental stress which the use of respiratory protective equipment may cause to workers and,
where necessary, prescribe breaks, restrictions on use or other such measures to be followed
to maintain the workers’ capacity for work.
5. Respiratory protective equipment is, in principle, intended for personal use. If the circumstances
require respiratory protective equipment to be worn by more than one worker, area manager
shall take appropriate measures to ensure that such use does not create any health or hygiene
problem for the different users.
6.4 Inspection
The user should be sufficiently trained and familiar with the respirator in order to be able to inspect
the respirator to ensure that it is in proper working condition. Respirators shall be routinely
inspected before and after each use by the wearer. Inspection should include the following:
(a) tightness of connections;
(b) the condition of the respiratory inlet covering;
(c) the condition head harness;
(d) the condition of valves;
e) the condition of connecting tubes;
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DOC.
SAFETY
DIVISION STEEL WORKS EFF. DATE 31.05.2005
STANDARD
SS/
DOC. # TITLE Respiratory protection REVISION 00
PROCESS-01
DUE FOR
SHEET 5 OF 9 01.06.2008
REVISION
COMP. BY S BISWAS SIGNED DATE 20.05.2005

SURESH
AUTH. BY SIGNED DATE 21.05.2005
KUMAR

(f) the condition harness assemblies;

(g) the condition of hoses;
(h) the condition of filters;
(i) the condition of cartridges;
(j) end of service life indicator;
(k) electrical components;
(l) shelf life date;
(m) pliability and signs of deterioration in rubber or elastomer parts
(n) the proper function of regulators, alarms and other warning systems.
6.5 Cleaning
Respiratory protective equipment that has been used shall be cleaned and disinfected before it is
issued by the area manager to another employee. Respirators maintained for emergency use shall
be cleaned and disinfected after each use. Respiratory protective equipment issued specifically to
an individual employee should be cleaned and disinfected on a regular schedule to maintain the
equipment in proper working order. The following cleaning and disinfecting procedure is
recommended:
1. Remove any filters, cartridges or canisters, and elastic straps.
2. Remove cartridges. Discard cartridges per recommendation from the work assessment. The
cartridges may need to be treated as hazardous waste, depending on where they were used.
3. Wash the face piece (breathing tube if applicable) in cleaner disinfectant (recommended by
manufacturer) and use hand brush to remove dirt.
4. Rinse in clean, warm water.
5. Air dry in clean area.
6. Inspect respirator parts for deterioration and replace as necessary (use only approved
manufacturers’ parts).
6.6 Storage
Respirators should be properly stored. Damage may occur if they are not protected from physical
and chemical agents such as vibration, sunlight, heat, extreme cold, excessive moisture or
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DOC.
SAFETY
DIVISION STEEL WORKS EFF. DATE 31.05.2005
STANDARD
SS/
DOC. # TITLE Respiratory protection REVISION 00
PROCESS-01
DUE FOR
SHEET 6 OF 9 01.06.2008
REVISION
COMP. BY S BISWAS SIGNED DATE 20.05.2005

SURESH
AUTH. BY SIGNED DATE 21.05.2005
KUMAR

damaging chemicals.
Improper respirator storage can deform the face piece and create a poor sealing surface, cause
damage to the straps and face piece, and potentially contaminate the respirator and cartridges.
Employees should protect their respirators by performing the following:
1. Stretch and manipulate rubber or elastomer parts with a massaging action to prevent them from
taking a “set” during storage.
2. Store respirator and cartridges in a clean, non-contaminated, readily accessible area.
3. Store respirator and cartridges in a clean plastic bag or container to protect against dust,
sunlight, heat, extreme cold, excessive moisture, or damaging chemicals.
4. Store respirators so that the face piece and exhalation valve rest in a normal position.
6.7 Training
Supervisors of respirator wearers, respirator wearers, emergency/ rescue teams and persons
issuing respirators must receive adequate training (and periodic retraining) by a qualified person.
Written records shall be maintained for same.
Each respirator wearer will be trained upon initial assignment to a respirator-required area and be
retrained annually or semiannually as required. The scope of training activities will include at a
minimum:
1. Instruction in the proper maintenance, inspection, storage, and use of respirators
2. Instruction in proper donning, fitting, and wearing of respirators
3. Performance of negative and positive pressure tests on air purifying respirators to ensure there
is no leak between the respirator and the face..
7.0 Monitoring & Reviewing
Frequency Mechanism Record Responsibility
1. Annual Inspection List of respirator waiver EHS co-ordinator
2. Annual Testing/ Fit testing & inspection record for all EHS personnel
Inspection chemical and air supplied
respirators
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DOC.
SAFETY
DIVISION STEEL WORKS EFF. DATE 31.05.2005
STANDARD
SS/
DOC. # TITLE Respiratory protection REVISION 00
PROCESS-01
DUE FOR
SHEET 7 OF 9 01.06.2008
REVISION
COMP. BY S BISWAS SIGNED DATE 20.05.2005

SURESH
AUTH. BY SIGNED DATE 21.05.2005
KUMAR

ANNEXURE-1
Non exhaustive Reference list of applications where respiratory protection may be
necessary:-

Work in containers, restricted areas and gas-fired industrial furnaces where there
may be gas or insufficient oxygen
Work in the vicinity of gas pipes
Work in the vicinity of heavy metal fumes
Work on the lining of furnaces and ladles where there may be dust
Spray painting where dedusting is inadequate
Work in shafts, sewers and other underground areas connected with sewage
Work in refrigeration plants where there is a danger that the refrigerant may escape
Work with asbestos
Work involving carcinogens
Work involving benzene and lead
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DOC.
SAFETY
DIVISION STEEL WORKS EFF. DATE 31.05.2005
STANDARD
SS/
DOC. # TITLE Respiratory protection REVISION 00
PROCESS-01
DUE FOR
SHEET 8 OF 9 01.06.2008
REVISION
COMP. BY S BISWAS SIGNED DATE 20.05.2005

SURESH
AUTH. BY SIGNED DATE 21.05.2005
KUMAR

ANNEXURE - 2
Non exhaustive list of Respiratory equipment applicable for different environment
(in use at Tata Steel)
Hazard / Name of Safety
Parts of body Stock No. Picture
Application for Appliance
129/4800
Dust Dust Respirators 129/4810
129/6685
Dust & Mist Dust & Mist 129/6686
Respirator for
Dust, Mist &
Dust, Mist & 129/6687
Nuisance odor
Nuisance odor
Respiratory
System & Lungs Metallic Fume Fume respirator 129/6688

Chlorine, Ammonia,
Acid & Organic Full visor gas
129/2520
Vapour up to 20 mask with canister
ppm

Chemical
Organic Vapour Cartridge 129/4815
respirator
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DOC.
SAFETY
DIVISION STEEL WORKS EFF. DATE 31.05.2005
STANDARD
SS/
DOC. # TITLE Respiratory protection REVISION 00
PROCESS-01
DUE FOR
SHEET 9 OF 9 01.06.2008
REVISION
COMP. BY S BISWAS SIGNED DATE 20.05.2005

SURESH
AUTH. BY SIGNED DATE 21.05.2005
KUMAR

Available at
Toxic Gases where Self contained Gas Safety
O2 % is less than Breathing Station & other
20% Apparatus relevant
locations
Toxic Gases where
Blower type Fresh
O2 % is less than 129/0110
Air Apparatus
Respiratory 20%
System & Lungs
Available at
Resuscitator /
For Semi First Aid, Gas
Pneupack /
unconscious / Safety Station
Oxypack / Life
breathing trouble other relevant
pack
locations.