RESPIRATORY PROTECTIVE EQUIPMENT (RPE)

IN
M/s LAURUS LABS LIMITED

A Project report submitted in

Partial fulfillment of the requirements for
The award of the certificate of the

INDUSTRIAL SAFETY

Submitted By
K. AMARENDRA
(2017- 2018)

IIFSE
(Institute of industrial fire and safety engineering)
Affiliated by State Board of Technical Education & Training
Thotapalem, Near RTC complex, Vizianagaram-535002.
Ph.:08922-232456

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 30th June 2018

TO WHOMSO EVER IT MAY CONCERN

This is to certify that below mentioned students from (IIFSE) Institute of Industrial Fire and
Safety Engineering, in Affiliation with State Board of Technical Education and Training,
Vijayawada, A.P Pursuing his Industrial Safety has under gone one month fifteen days Internship
Project from May 15th 2018 to June 30th 2018 in M/s LAURUS LABS LIMITED on, Entitle
Respiratory protective equipment (RPE) in the Industry.

1. K. Amarendra.
2. K. Veerababu.
3. K. Ramakrishna.
4. M. Krishna.
5. Ch. Nagarjuna.

During his stay we found his performance is good and satisfactory.

We wish you all the very best in your future Endeavor.

For,
Factory Seal & Authorized signatory

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 CERTIFICATE

We certify that the project work entitled Respiratory protective equipment (RPE) submitted by

Mr. K. Amarendra for partial fulfillment of Industrial Safety to the State Board of Technical

Education and Training affiliation with Institute of Industrial Fire and Safety Engineering

(IIFSE) Vizianagaram, during the year of 2017 - 2018.

Place:

Date: Head of the Department

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 DECLARATION

We hereby declare that the present project work described in this project Respiratory protective

equipment (RPE) has been carried out by me under the guidance of Laurus Labs Limited.

The work is original and has not been submitted previously, in part or full to any other university

for any Degree of fellowship.

Place:

Date:

Names Signature

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 EHS POLICEY OF LAURUSLABS
Laurus Labs is committed to continually improve Environment, Health & Safety (EHS)
performance in Research & Development, Contract Services and Manufacturing of
Pharmaceutical Products with focus on...

 Protection of environment including prevention of pollution through eco-friendly

processes and practices.
 Protect and promote the “health and wellbeing of employees” by integrating good
occupational health and hygiene practices.
 Equip, establish and operate facilities with the “highest safety standards” to protect
personnel from any hazard.
 Comply with all EHS obligations i.e. legal, regulatory, customer, society and other
requirements.
 Communicating to all interested parties, their EHS obligations.

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Page 6 of 49
 List of content

S. No. Topic Names

1 Introduction
2 Personal Protective Equipment (PPE’s)
3 Non-Respiratory Protective Equipment
4 Respiratory Protective Equipment
5 RPE explained
6 RPE types
7 PAPR (Powered Air Purifying Respirator).
8 Self-Contained Breathing Apparatus (SCBA)
9 Quality of air for breathing apparatus
10 Usage of RPE
11 CE marking
12 Regulations
13 Respiratory Hazards.
14 Selection of RPE
15 Maintenance
16 Disposal
17 Storage
18 Fit testing
19 Legal requirements
20 Hazardous substances
21 Implementing RPE use in the workplace
22 Designated areas
23 Management and supervision
24 Training
25 Misuses of RPE
26 Observations and Conclusions

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 INTRODUCTION

Many workers wear respirators or breathing apparatus to protect their health in the workplace.
These devices are collectively known as respiratory protective equipment (RPE). This guide
will help those who have responsibility for the use of RPE at work. You may be an employer
or self-employed. It supports the Approved Code of Practice (ACOP) to the Regulations that
apply. As an employer, you have a legal responsibility under all the Regulations listed to
control substances hazardous to health in your workplace, and to prevent and adequately
control your employees’ exposure to those substances. Provision of RPE may be necessary as
part of your control regime.

The guide assumes you are considering the use of RPE based on your COSHH risk assessment
(Control of Substances Hazardous to Health Regulations 2002). The hazard and risk
information gathered in your COSHH risk assessment is required to select the correct RPE.
The guide contains practical guidelines to help you select the correct RPE and manage its use
in your workplace to ensure effective protection. The process of selection and management of
RPE is split into key steps. The guide has been color-coded to help direct you through the
process

Those responsible for managing staff health and safety, safety representatives, health and
safety specialists, manufacturers and suppliers of respiratory protective equipment (RPE) will
find this guide useful.

The law requires you to prevent or control the exposure of employees and others to hazardous
substances at work. Before using RPE, exposure should be controlled by reasonably
practicable measures other than the use of personal protective equipment (PPE).

So you should use PPE only as a last line of protection to control the exposure. Use this guide
if you are at the point of wanting to provide RPE as a last line for controlling exposure to
hazardous substances. To select the right RPE you will have to take account of the properties
of the hazardous substances, the needs of the wearer, the work and workplace conditions. This
guide will help you to do that. It follows a step-by-step approach to deciding the minimum
level of protection you need from the RPE. The decision is based upon the severity of the
health hazard of the substance, the amount of substance your employees are exposed to and
how easily they can breathe it in. The choice of correct RPE is based on the wearer and
workplace requirements. Other issues you will need to consider when using RPE are also
described.

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2.1 Personal Protective Equipment (PPE’s)

2.1 Proper selection, usage and maintenance of respiratory and non-respiratory PPE for
handling of chemicals/ materials/ equipment’s.

2.2 Specifies necessary personal protective equipment which is to be used by personnel

for protection against known hazards.

2.3 Protective wearing apparel, when used properly, designed to reduce or eliminate
injuries to personnel.

2.4 Selection of PPE with associated Hazards identified chart given below.

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RPE -

Respiratory Protective Equipment PP - Positive Pressure

SCBA - Self Contained Breathing Apparatus IDLH - Immediate Danger to Life or Health
PAPR - Powered Air Purifying Respirator

PERSONAL PROTECTIVE EQUIPMENTS (PPE’s)

Personal protective equipment’s can be broadly classified in two categories:

PPE

NON-RESPIRATORY RESPIRATORY
PROTECTIVE EQUIPMENTS PROTECTIVE EQUIPMENTS
(Broadly divided into Two types)

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Non-respiratory protective equipment’s
are use full to the below parts protection.

Air supply Air purified

1 Head protection
2 Ear protection 1. Bubble hood 1. Filtering devices
3 Eye & Face protection 2. Online Air Mask (Dust
practical’s)
4 Hand protection 3. PVC Air Suit 2. Gas/vapours filters
5 Leg & Foot protection 4. Delta suits 3. PAPR.
6 Body Protection height protection 4. SCBA, ELBA.
7 Roof top safety ladder or Duck ladder.
8 Helmet, Head cap
9 Shoes, Gum shoes
10 Goggle, Face shield
11 Protective clothing
12 Ear Muff, Plug
13 Safety belt, Net
14 Hand gloves

3.2 Non-Respiratory Protective Equipment

3.3 Respiratory Protective Equipment

3.4 RPE explained

Work activities may result in harmful substances contaminating the air in the form of
dust, mist, vapor, gas or fume. For example, when:
1. Cutting a material such as stone or wood;
2. Using a product containing volatile solvents;
3. Handling a dusty powder;
4. Welding stainless steel.
Workers may also need to work in areas where oxygen levels are or may become low,
for example: Confined spaces, such as a trench, silo or tank.
RPE is a particular type of personal protective equipment (PPE) designed to protect the
wearer from breathing in harmful substances or from oxygen-deficient atmospheres
when other controls are either not possible or insufficient on their own.

3.5 RPE types

There are many different RPE types designed to:

1 Protect the wearer from a variety of hazards;
2 Suit a variety of work situations;

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 3 Match the specific requirements of the wearer.
RPE is available in different sizes to allow for the facial differences of workers. Gender,
ethnicity, build and many other factors mean that one size of face piece will not fit
everyone.

RPE must be both adequate and suitable:

Adequate- It is right for the hazard and reduces exposure to the level required to protect
the wearer’s health.
Suitable- It is right for the wearer, task and environment, such that the wearer can work
freely and without additional risks due to the RPE.
Respirators (filtering devices) use filters to remove contaminants from the air being
breathed in. They can be either: Non-powered respirators-relying on the wearer’s
breathing to draw air through the filter powered respirators-using a motor to pass air
through the filter to give a supply of clean air.

3.6 PAPR (Powered Air Purifying Respirator):

3.6.1 THEORY OF OPERATION

The user of the respirator breathes ambient air after the air has passed through a
pair of filter elements. The filter elements may include a mechanical filter to trap
airborne particulates or a sorbent bed of impregnated activated carbon to trap
and/or neutralize various gases and vapors. Filtration elements must be selected
specifically to suit the hazardous atmosphere application.
The full face piece is intended to seal against the user’s face and allows the user to
breathe the air drawn through the filter elements. An inhalation check valve
prevents exhaled air from entering the blower assembly. The exhalation valves
allow the exhaled breath to exit the face piece into the surrounding atmosphere.
The inhalation and exhalation valves are integral to the face piece or face piece
adapter.
The blower assembly assists breathing by drawing air through the filter elements
and delivering the purified air through the breathing tube to the face piece. When
the blower assembly is used with the blower switch ON, the positive pressure
inside the face piece affords the greatest level of protection to the user from the
contaminants in the atmosphere.

To maintain this level of protection:

1. The user must be properly fit tested to the tight fitting respirator face piece
before use.
2. The blower must be tested with the Airflow Indicator with filtration elements
installed both prior to use and at prescribed intervals during use to monitor the
battery life and filter element efficiency.
3. The blower must always be used with the power switch ON when the respirator
is used in a contaminated atmosphere.

3.6.2 Breathing apparatus needs a supply of breathing-quality air from an

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 independent source

3.7 SELF CONTAINED BREATHING APPARATUS (SCBA)

Respiratory protection for atmospheres that are too toxic to be filtered or with oxygen
deficiency

3.7.1 Protection from

 Emergencies
 Oxygen deficient area
 Irrespective of contaminants & Concentration.
 No restriction of wearer movements
 More reliable than others
 Cylinder pressure exhaust on use
 Wearer need training and skill

3.7.2 WHERE THE APPLICABLE

 Gas leak
 Solvent leak
 Ammonia leak
 Explosions
 Fire
 Chlorine leakage

3.7.3 COMPONENTS OF SCBA

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3.7.4 OPERATING PROCEDURE

 Check the pressure of the cylinder for assessment of service time.

 The cylinder pressure must be at least 270 bars for 300 bar cylinder.
 Check harness and keep straps wide open.
 Put apparatus on back with straps fully extended.
 Tighten shoulder straps till carrying plate fits comfortably.
 Close waist belt with buckle such that the
 Opening button of the buckle faces the body.
 Pull & open cylinder valve with approx. two turns in anti-clock wise direction.
 Insert face piece such that chin seats perfectly and pull on belts overhead.
 Adjust shoulder straps until the desired weight distribution between shoulders
and hips is attained.
 Hang the belt of the full face mask round the neck
 Hold the mask in position and tighten the side straps on temple region first
 Next, pull the bottom straps away till the mask fits comfortably.
 Now, pull the top strap on the head.
 Take deep breathe to open the lung demand valve.
 The apparatus is tight if the pressure drop after 1 minute does not exceed 10
bar.
 After the usage, loosen the side straps and hold the face piece
 Press the demand valve to disconnect the supply of air.
 Lift off the face mask and further loosen the straps.
 Pull the cylinder valve and turn clockwise to close.
 Slowly release pressure by pressing the demand valve observing pressure

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 gauge at the same time.
 Remove the apparatus and keep in the designated place.
Note: The warning signal will begin to sound at 55±5 bar and immediately
the wearer should come out of the toxic atmosphere

SCBA LIMITATIONS

 Cylinder pressure exhaust on use

 Wearer need training and skill
 Special training needs eg: Buddy breathing
 Competency to maintain equipment
 More expensive.

3.8 Filters:

A key component of any respirator is the filter. Filters are available for solid or liquid
particles, vapors and gases. They can be an intrinsic part of the device or come
separately so they can be changed on a reusable respirator.
It is vital that you choose the correct filter, which will be effective against the hazard,

S.
Name & code Picture
No.
MODEL: 3M 9004
01 Usage: Dust Respirators

MODEL: 3M 8710
02 Usage: Dust/Mist Respirators

MODEL: 3M 9913
03 Usage: Dust, Mist or Organic vapour
Respirators

MODEL: 3M 8210
04 Usage: N95 Welding Respirators

MODEL: 3M 8246
05 Usage: Acid gas Relief Respirator

MODEL: 3M 8822
06 Usage: FFP2 Welding Respirator

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 MODEL: 3M 8511
07 Usage: N95 Respirator

MODEL: 3M 6003
08 Usage: Organic Vapor/ Acid gas Cartridge

MODEL: 3M 6004
09 Usage: Ammonia/ Methyl Amine Cartridge

MODEL: 3M 6006
10 Usage: Multi gas/vapor Cartridge

ID No Uses
Maintenance Free Respirators
3M 9004 Dust Respirator
3M 8710 Dust/Mist Respirator
3M 9913 Dust, Mist or Organic vapor Respirator
3M 8210 N95 Welding Respirator
3M 8246 Acid gas Relief Respirator
3M 8822 FFP2 Welding Respirator
3M 8511 N95 Respirator
Elastomeric Face piece Respirators

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 3M 6001 Organic vapor cartridge
3M 6002 Acid gas cartridge
3M 6003 Organic vapor/Acid gas cartridge
3M 6004 Ammonia/Methyl Amine cartridge
3M 6005 Organic vapor/Formaldehyde cartridge
3M 6006 Multi gas/ vapor cartridge
3M 6009 Mercury/Chlorine cartridge
3M 2091 P100 Particulate filter
3M 501/5N11 Filter Retainer / Pre Filter

3.9 Changing of filter:

Particle filters: Particle filters will become clogged and make breathing difficult,
possibly resulting in face seal leaks.

The following is recommended:

1 For TH and TM type filters for fan-assisted respirators, change as instructed by the
manufacturer.
2 For replaceable filters, it would be good practice to mark the filter visibly with the
date it was taken out of the packaging and fitted to the RPE; an in-house replacement
date can be added to this marking.

Changing particle filters:

1. Do not use if the shelf-life expiry date on the filters has passed.
2. Change when filters are damaged or visibly contaminated.
3. Change when they become harder to breathe through. This can happen quickly if the
wearer is exposed to very high dust concentrations.

3.10 Gas/ vapor filters

1 Gas/vapour filters have a limited capacity for removing gases/vapours, so after a time
the gas or vapour will pass straight through. This is known as breakthrough. When
breakthrough occurs, the RPE offers no protection.
2 Filter life is very difficult to predict because it depends on a large number of factors.
They don’t last forever.
3 The following is recommended:

Filter capacity 1
Change at least every two days or as instructed by the manufacturer; but if the filter is
used for protection against a:carcinogen;
Respiratory sensitiser;

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 1 Potential carcinogen;
2 Substance that may cause allergy or asthma symptoms or breathing difficulties if
inhaled;
3 Change every day, or as instructed by the manufacturer.

Filter capacity 2

Change at least once a week or as instructed by the manufacturer. For capacity 3 and
TM/TH type filters, you should change as instructed by the manufacturer.
For replaceable filters, it is good practice to mark the filter visibly with the date it was
taken out of the packaging and fitted to the RPE; an in-house replacement date can be
added to this marking.

3.11 Changing gas/ vapour filters:

Change filters as instructed by the manufacturer; for example, AX filters are single use
only and mercury (Hg) filters have a maximum use time of 50 hours.

1 Change before any expiry date marked on the filter.

2 Do not use if the expiry date on the filters has passed.
3 Change when damaged or visibly contaminated.
4 Change before the contaminant can be smelled or tasted.
5 Change before the filter life indicated in your risk assessment.

Air - line Respirators

1 Bubble hood
2 Delta suit
3 PVC Air Suit
4 Online Air Mask

3.12 PAPR (Powered Air Purifying Respirator):

Theory of Operation
The user of the respirator breathes ambient air after the air has passed through a pair of
filter elements. The filter elements may include a mechanical filter to trap airborne
particulates or a sorbent bed of impregnated activated carbon to trap and/or neutralize
various gases and vapors. Filtration elements must be selected specifically to suit the
hazardous atmosphere application.

The full face piece is intended to seal against the user’s face and allows the user to
breathe the air drawn through the filter elements. An inhalation check valve prevents
exhaled air from entering the blower assembly. The exhalation valves allow the exhaled
breath to exit the face piece into the surrounding atmosphere. The inhalation and

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 exhalation valves are integral to the face piece or face piece adapter.

The blower assembly assists breathing by drawing air through the filter elements and
delivering the purified air through the breathing tube to the face piece. When the blower
assembly is used with the blower switch ON, the positive pressure inside the face piece
affords the greatest level of protection to the user from the contaminants in the
atmosphere.

To maintain this level of protection:

1. The user must be properly fit tested to the tight fitting respirator face piece before
use.
2. The blower must be tested with the Airflow Indicator with filtration elements
installed both prior to use and at prescribed intervals during use to monitor the
battery life and filter element efficiency.
3. The blower must always be used with the power switch ON when the respirator is
used in a contaminated atmosphere.

4. Breathing apparatus needs a supply of breathing-quality air from an independent

source

5. Half face breathing mask

3.13 Quality of air for breathing apparatus

Air quality: Air supplied to breathing apparatus (BA) should be clean and safe to
breathe, whether it is supplied via a fresh air hose or a source of compressed air.

Fresh air hose:

You should securely anchor the inlet for fresh air hose BA in an area that is free of
contaminant. This can usually be achieved by siting the inlet well away from the work
area (eg in free air outside the building), and upwind of any local sources of airborne
contamination (eg vehicle exhaust).

Compressed air

Compressed air for BA normally originates from a compressor system. The

maintenance, examination and testing of compressors should be carried out according
to the manufacturer’s instructions. The siting of air inlets to compressors should follow
the same principles as for fresh air hose. However, because compressors themselves
can generate and concentrate a wide range of contaminants, you should take extra care
in assuring air quality.

As the BA wearer’s life and health depend on the air supplied by the compressor, you
should ensure that the air supplied meets the quality requirements in British Standard
BS EN 12021 In addition to the pressure and airflow rate requirements of the BA

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 manufacturer.

Compressors which are moved from site to site, such as those used by the emergency
services or on construction sites, will require a higher standard of maintenance and
should be sited so that the quality of air they provide is not compromised by nearby
contaminants.

Compressed air for breathing apparatus shall not contain any contaminants at a
concentration which can cause toxic or harmful effects. In any event all contaminants
shall be kept to as low a level as possible and shall be far below the national exposure
limit. Combination effects of more than one contaminant shall be taken into account.’
(1999)

3.14 Periodic testing of air quality

The purpose of periodically testing air quality is to make sure that the control measures
you have put in place are delivering the air quality required by BS EN 12021. You
should base the frequency of such tests on a risk assessment, but they should take place
at least every three months, and more often when the quality of air cannot be assured to
these levels.

As part of the risk assessment, if a mobile compressor is being used consideration

should be given as to how often the air supply should be checked when the compressor
is moved. Testing for these components may be carried out using any appropriate
method, eg:
15 simple colour change tubes;
16 on-line gas testers;
17 Sample collection for laboratory analysis elsewhere.
The supplier of your compressor or BA should be able to advise you on the best method
for you. You should keep records of air quality tests for five years.

3.15 Usage of RPE

The laws governing the control of harmful substances in the workplace, and their
supporting ACOP, say that you should only use RPE after you have taken all other
reasonably practicable measures to prevent or control exposure. By going through the
risk assessment process required by these laws, you can determine whether the use of
RPE is necessary in your workplace. If you write your justification for using RPE on
your risk assessment record you should remember the reasons behind your chosen
control regime and be able to adapt it in the future as necessary. If you have fewer than
five employees you are not legally required to record your risk assessment.

You should only select and use RPE:

1. where an inhalation exposure risk remains after you have put in place other

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 reasonable controls (residual risk);
2. while you are putting in place other control measures (interim measures);
3. Emergency work or temporary failure of controls where other means of control are
not reasonably practicable for short-term or infrequent exposure, such as during
maintenance work, where you decide that other controls at the source of the
exposure are not reasonably practicable
There are situations where specialist advice may be needed to select the right RPE.
These include:
1. Emergency escape- where you need to provide RPE for safe exit from an area
where hazardous substances may be released suddenly after control systems fail;
2. Emergency rescue.
3. Under the law, RPE is the last line of protection. Remember, RPE can protect only
the wearer and if it is used incorrectly, or is poorly maintained, it is unlikely to
provide the required protection. Note also that RPE can be uncomfortable to wear
and may interfere with work, which can lead to incorrect use.

3.16 Specific requirements for RPE use

RPE at work should:

1. Adequately control inhalation exposure to provide the wearer with effective
protection;
2. Be suitable for the intended use;
3. Be CE-marked of an approved type/standard approved by HSE;
4. Be used by properly trained people who are supervised;
5. be properly stored, cleaned and checked regularly to ensure it remains effective.
6. Adequate RPE is right for the hazard and reduces exposure to the level required to
protect the wearer’s health.
7. Suitable RPE is right for the wearer, task and environment, such that the wearer can
work freely and without additional risks due to the RPE.
8. Employers should make sure the selected RPE is of the right size and can correctly
fit the wearer. For tight-fitting face pieces the initial selection should include a fit
test.
9. In addition, you must ensure that reusable RPE undergoes thorough examination
and, where appropriate, testing at suitable intervals. This should be monthly, or
every three months if used less frequently. This will not only make sure the RPE
protects the wearer but will also extend the life of the equipment and so maximize
your investment.
10. You should record RPE examinations and tests – and, where appropriate, any
repairs made – and retain them for at least five years. The records will help to keep
track of the equipment’s maintenance.
11. You should test the quality of air supplied to BA at least once every three months.
For RPE to be effective, you should integrate its use into normal workplace
activities.
12. You should also ensure that RPE is used according to the manufacturer’s
instructions, as poor working practices or improper use can significantly reduce its
effectiveness.

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3.17 CE marking

RPE used at work must be manufactured in accordance with the Personal Protective
Equipment Regulations 2002.4 In practice; this means you need to use CE-marked
equipment. The CE mark on

RPE tells you that the equipment has met the minimum legal requirements for its
design.
This marking appears as the letters ‘CE’ and a four-digit code that identifies the body
responsible for checking manufacturing quality

CE marking does not indicate that an RPE device is automatically adequate and
suitable for use in your workplace. It is your responsibility to select the correct RPE to
meet your specific requirements.

3.18 Regulations

The Health and Safety at Work etc Act 19745 and the Management of Health and
Safety at Work Regulations 1996 require you to provide and maintain a safe working
environment, so far as is reasonably practicable. They set out the basic requirements
for you to follow.
In addition to the COSHH Regulations 2002, RPE may need to be used to satisfy
requirements in the following pieces of legislation. You will need to consider whether
any of these Regulations apply to you and comply with any specific requirements they
contain on RPE:
1. Control of Asbestos Regulations 2012
2. Control of Lead at Work Regulations 2002
3. Ionizing Radiations Regulations 1999
4. Confined Spaces Regulations 1997

These Regulations are supported by Approved Codes of Practice. ACOPs give practical
guidance on compliance and have a special status in law. If you are prosecuted for a
breach of health and safety law, and it is proved that you did not follow the relevant
provisions of the code, you will need to show that you have complied with the law in
some other way or a court will find you at fault.
For RPE use that is not covered by any of the above Regulations, employers and
employees have duties under the Personal Protective Equipment at Work Regulations
1992.

3.19 RESPIRATORY HAZARDS

1. Oxygen deficiency
2. Asphyxiation
3. Toxic gas, Fumes
4. Dust, Particulate matter

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 5. Hot air / gas.

3.19.1 Selection of RPE:

You will require RPE that is adequate and suitable to ensure the wearer is
protected. This means:

Adequate – It is right for the hazard and reduces exposure to the level required
to protect the wearer’s health

Suitable – It is right for the wearer, task and environment, such that the wearer
can work freely and without additional risks due to the RPE
3.20 To select RPE that will protect the wearer you will need a basic understanding of:

1. The hazardous substance and the amount in the air (exposure);

2. The form of the substance in the air (Ex.: gas, particle, vapor);
3. The type of work being carried out;
4. Any specific wearer requirements, such as other PPE or a need for spectacles.

If there is a likelihood of the atmosphere in which the RPE will be used being deficient
in oxygen, or if the concentration of substance in the air could be life-threatening,
specialist BA is required. Only those with appropriate training should use this type of
BA. The use of RPE in oxygen-deficient atmospheres is not covered in this guide and
specialist advice may be needed.

3.21 Selecting RPE adequate against the hazard

3.21.1 Identifying the exposure hazard

You will have been through the COSHH risk assessment process to identify the
hazardous substances in your workplace. As a reminder, there are two key
areas to consider

Products you use at work that are hazardous substances will come with a safety
data sheet (SDS) provided by the supplier. Any product classed as ‘dangerous
for supply’ must come with this sheet by law and it should contain information
on
1. Health hazards (product labelling);
2. Forms of the substances contained in the product;
3. Type of RPE necessary for its use.
Work activities, such as cutting or heating materials, may generate harmful
substances, which contaminate the air in the form of dusts, mists, gases or
fumes. Further information on these substances is given in a series of COSHH
essentials guidance sheets.

3.21.2 Forms of substance

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 Hazardous substances can be present in the air as particles (solid or liquid),
vapour or gas. Under certain conditions, they can exist in more than one form
at the same time (eg during paint spraying). You need to identify the form of
the hazardous substances in the air to select the right RPE.
Note that:
 Solid and liquid forms will be present as particles;
 Fine sprays and mists are made up of liquid particles (droplets);
 Fumes are very fine solid particles and not gas or vapour;
 Smoke, fume and airborne liquids require RPE that is suitable for use
against particles.
 In addition to the above, volatile liquids may under certain conditions
become airborne as both particles and vapour.
3.22 Examples of the different forms of hazardous substances

Form Properties Examples

Asbestos dust
Engine exhaust particles and fume
Lead dust and fume
Particles of solid material, Stone dust
Solid particles including aerosols, dusts, Welding fume
fibers, smokes and fume Wood dust
Smoke
Fungal spores and parasites
Bacteria and viruses, Flour
Sprayed liquids:
paints
pesticides
Fine sprays, mists and
powder coating mix
Liquid particles aerosols made up of small
liquid jetting
droplets of liquid
Mists:
chrome acid
cutting fluids, oil mist
Solvent vapor
Gaseous forms of a solid or
Vapor Mercury,
liquid
vapor
Carbon monoxide
Gas -- Engine exhaust gases,
Sewer gas, Chlorine

3.23 Matching filters to the substance and its form

There are various types of respirator and they all rely on filter material to remove the
hazard. The filter material will be different depending on the hazardous substance and
its form.

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 There are two basic filter types available:
1. Particle filters;
2. Gas/vapour filters.

Remember that airborne liquids in the form of fine sprays and mists and solid materials,
including dusts, fibers, smoke and fume, require a particle filter.
As air is breathed in, it passes through the filter(s), removing the contaminants before
they reach the lungs.

The respirator can either:

1. Be made of the filter material;
2. Have a filter(s) fitted to it; or
3. Use a motor to pass air through the filter(s) that may be separate from the face piece
Remember:
4. Particle filters do not protect against gas or vapour.
5. Gas/vapour filters do not protect against particles.
6. Neither filter type can be used in oxygen-deficient atmospheres.
Some situations require a combination of filters suitable for the different substances or
forms present.

3.24 Maintenance

Maintenance is a requirement for all RPE, except for disposable (single use) RPE, and
should be carried out by properly trained personnel. Thorough maintenance,
examination and tests should be carried out at least once a month. However, if the RPE
is used only occasionally, an examination and test should be carried out before use
and, in any event, the interval should not exceed three months. Emergency escape-type
RPE should be examined and tested in accordance with the manufacturer’s
instructions.
There are five key points you should follow when carrying out RPE maintenance:
1. Follow the manufacturer’s instructions.
2. A competent person should carry out the work.
3. Keep records
4. Ensure the intervals for maintenance are appropriate.
5. The maintenance programme should reflect the complexity of maintaining the RPE.

Ideally, any parts that require replacing will be sourced from the original manufacturer
of the RPE. This will ensure any replacement parts continue to allow the equipment to
operate as originally intended and perform to the standards that ensure the RPE offers
the protection stated by the manufacturer.

You must keep records of examination and testing, and any repairs made, for at least
five years.
Key maintenance tasks include:
1. changing any replaceable filters;

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 2. cleaning the device;
3. valve maintenance and replacement;
4. checking the straps for damage;
5. Checking the battery charge and flow rate for powered devices.

Filters only have a limited capacity, or can become clogged, making breathing difficult.
Replaceable filters should be changed when necessary to make sure the RPE device can
remain effective. See Appendix 2 for more information.

Cleaning a reusable facepiece is required to remove contamination, moisture build-up

and microbes. The manufacturer should provide advice on cleaning and inspection of
the RPE, including on the appropriate cleaning materials and disinfectants to use. The
use of cleaning products other than those recommended by the manufacturer may cause
problems with the RPE.

Cleaning and drying should be carried out in a clean area to avoid contamination of the
RPE.

3.25 Disposal

Contaminated RPE, or components, or any of the materials used to clean or disinfect

the RPE, may need to be considered as hazardous waste. This will depend on the
specific substances and the amounts involved. In some cases, specific legislation may
apply. If in doubt, seek specialist help.

3.26 Storage:

Remember that all RPE requires clean storage facilities. The following is a general
guide:
1. RPE should be stored in accordance with the manufacturer’s user instructions in
order to prevent contamination, damage and deterioration.
2. RPE should be cleaned before being stored to prevent the storage area becoming
contaminated.
3. Provide storage that is easily accessible so that RPE can be safely stored during
breaks.

3.27 Air quality:

Air supplied to BA should meet minimum quality requirements, in line with the latest
British Standard. Your RPE or air compressor supplier should be able to advise you on
how to meet these requirements.

3.28 Fit testing:

Face piece fit testing is a method of checking that a tight-fitting face piece matches
the wearer’s facial features and seals adequately to their face. It will also help to

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 identify unsuitable face pieces that should not be used. You should carry out a fit test
as part of the initial selection of the RPE. Remember that tight-fitting RPE will only
provide effective protection if the wearer is clean shaven, so they should also be clean
shaven when fit tested.

The performance of tight-fitting face pieces depends on achieving a good contact

between the wearer’s skin and the face seal of the face piece. People’s faces vary
significantly in shape and size so it is unlikely that one type or size of RPE face piece
will fit everyone. Inadequate fit will significantly reduce the protection provided to the
wearer. Any reduction in protection can put the RPE wearer’s life in danger or may
lead to immediate or long-term ill health.

Fit testing can also serve as a useful training tool for teaching the wearer how to put on
their face piece correctly. Correct fitting of the face piece at all times is vital to prevent
exposure.

A fit test does not remove the need for correct and careful day-to-day fitting of the face
piece, which should always include a fit check.
A fit test should be carried out:

1. As part of the initial selection of the RPE;

2. Where an untested face piece is already in use.

It is good practice to have a system in place that ensures you carry out repeat fit testing
of RPE on a regular basis. This is especially important when RPE is used frequently as
a primary means of exposure control, eg annual testing for workers involved in
licensed asbestos removal. You may find it useful to keep records of fit testing.

You should always conduct a repeat fit test if the wearer:

1. loses or gains weight;
2. undergoes any substantial dental work;
3. Develops any facial changes (scars, moles etc) around the face seal area.

Where face pieces are issued on an individual basis it is recommended that the wearer
is fit tested using their ‘own’ face piece. Where this is not practicable, or pooled
equipment is used, then a test face piece that exactly matches the wearer’s ‘own’ face
piece (model, size and material) should be used.

When considering fit testing give thought to whether the wearer will need to use other
PPE to ensure it is compatible and does not interfere with the protection offered by
the RPE.

3.29 There are two basic types of RPE fit testing:

Qualitative and Quantitative.

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3.30 Qualitative fit testing

Qualitative fit testing is a pass/fail test based on the wearer’s subjective assessment of
any leakage from the face seal region, by sensing the introduction of a test agent.
These tests are suitable for half masks. They are not suitable for full face masks.
Examples of qualitative fit testing methods are:
1. Method based on bitter- or sweet-tasting aerosol;
2. Method based on odour compounds.

3.31 Quantitative fit testing

Quantitative fit testing provides a numerical measure of the fit, called a fit factor.
These tests give an objective measure of face fit. They require specialized equipment
and are more complicated to carry out than qualitative methods. Quantitative methods
are suitable for full face masks (but can also be used for half masks). Examples of
quantitative fit testing methods are:
1. Laboratory test chamber;
2. Portable fit test devices, such as a particle counting device.

3.32 Competence:

RPE fit testing should be conducted by a competent person. Competence can be

demonstrated through achieving accreditation under Test Providers’ Accreditation
scheme. This scheme has been developed by the British Safety Industry Federation
(BSIF) together with industry stakeholders and is supported by HSE. The scheme is
not compulsory and you are free to take other action to comply with the law.

3.33 Legal requirements

Regulations: The Health and Safety at Work etc Act (HSWA)3 and the Management
of Health and Safety at Work Regulations (MHSWR)4 require you to ensure that you
have a safe working environment. They set out the basic requirements for you to
follow. These are the principal health and safety regulations from which all others
follow.
The law governing the use of RPE is contained in:

1. The Control of Substances Hazardous to Health Regulations (COSHH);

2. The Control of Asbestos at Work Regulations (CAW);
3. The Control of Lead at Work Regulations (CLAW)
4. The Ionizing Radiations Regulations (IRR);
5. The Confined Spaces Regulations (CSR)

These regulations are supported by Approved Codes of Practice (ACOPs).The Health

and Safety Commission (HSC) approve these. ACOPs have a special status in law. If
you are prosecuted for a breach of health and safety law, and it is proved that you did
not follow the relevant provisions of the code, you will need to show that you have

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 complied with the law in some other way or a court will find you at fault.

This guide on RPE supports the ACOPs to the regulations. If you use other PPE
(Ex. helmet, eye protection) in addition to RPE then you will also have to work
according to the Personal Protective Equipment at Work Regulations

3.34 Consulting employees and safety representatives

When implementing health and safety measures, which includes the selection and use
of RPE, you must consult either:
1. Safety representatives appointed by recognised trade unions; or
2. Employees, either directly or indirectly, through elected representatives.
3. Guidance on this matter can be found in the free HSE leaflet

3.35 Specific requirements for RPE use

1. The law says that RPE used at work must:

2. Be adequate and provide the wearer with effective protection;
3. Be suitable for the intended use;
4. Be ‘CE’-marked;
5. Be selected, used and maintained by properly trained people;
6. Be correctly maintained, examined and tested;
7. Be correctly stored.

3.36 RPE

RPE should only be selected and used after a justification has been made in the risk
assessment required by law. It can be used in the following situations:

Where an inhalation exposure risk remains after you have put in place other reasonable
controls (residual risk);

Short-term or infrequent exposures where you decide that other controls at source are
not reasonably practicable;

while you are putting in place other control measures (interim measures); emergency
escape-you need to provide RPE for safe exit from an area where hazardous
substances may be released suddenly in the event of control systems failures;
emergency work or temporary failure of controls where other means of controls are
not reasonably practicable; emergency rescue by trained personnel is necessary.

However, there may be circumstances where you may consider it prudent to issue PPE
including RPE, not because other control measures are inadequate on their own, but to
provide additional protection if any of the control measures fail to operate. In this type
of situation, it is prudent to seek specialist support (eg an occupational hygienist).

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3.37 Hazardous substances

Basic understanding of hazardous substances, their forms, and the way people can be exposed
to them, is essential for the selection of adequate and suitable RPE. Paragraphs 24-36 provide
help.

3.38 Forms of substance

Substances can exist as solids, liquids or gases. Under certain conditions, they can exist in
more than one form at the same time (Ex.: during paint spraying).

Particulate solids include aerosols, dusts, fibres, smokes and fume. Dusts and fibres are fine
particles that are released into the air. Fumes are generated by vaporisation of solids and
condensation into fine particles. Smokes are formed by the incomplete combustion of
materials. If the solid particulates are very fine, they can behave like gases and vapours and
move with air currents. In this way, they can be transported quite a long way from the source
of emission.

Liquids can exist as droplets or as finer sprays and mists in air or other gases.
Gases are like air and behave in the same way.
Vapours are the gaseous forms of substances, which normally exist as a solid or liquid
at room temperature. These are sometimes wrongly referred to as fumes, and this
terminology is not used in this guidance.
Provides a few examples relevant to RPE selection.

Solids Liquid Gases/vapour

s s
Asbestos dust Sprayed droplets Ammonia
Engine exhaust  paints Carbon monoxide
particles  pesticides Carbon dioxide
Lead dust and fume  powder coating mix Freons
Silica dust  liquid jetting Helium
Welding fume  sewage water Nitrogen
Shot blasting dust Mists Mercury vapour
Wood dust  chrome acid Solvent vapours
Smoke  cutting fluids Engine exhaust
Fungal spores  oil mist gases
Bacteria
Virus
Parasites

3.39 Routes of entry

Substances can enter the body through the lungs by inhalation or through the skin or
eyes or mouth. Each of these routes of entry may require protection in their own right.
You should consider all routes of entry when selecting PPE, including RPE.

3.40 Effects on the body

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 Substances can cause:
long-term (chronic) damage;
short-term (acute) damage; or they can act together to be more potent than alone
(synergistic). For example, cadmium can cause long-term effects of severe organ
damage to the kidney and lungs. Less well known are the short-term effects of sore
throat and flu-like symptoms. Substances can have multiple effects, causing local
damage at the point of entry and systemic damage to other organs in the body, or
sensitizing the skin or causing asthma. The effects of polyurethane spray paints are a
good example of sensitisation of the respiratory system as well as other organ damage
due to solvents.
3.41 Other hazardous situations
The hazardous substances we have covered so far are hazardous by nature; it is
inherent in their properties. There are also inhalation hazards that are not due wholly to
the properties of a particular substance.
3.42 Oxygen deficiency
The air we breathe is made up primarily of nitrogen (78%) and oxygen (20.8%) and
the amount of oxygen is critical to life. The level of oxygen in air can be reduced by
chemicals (eg when something is burning), biological agents (eg in metabolism) and
asphyxiants (when they dilute the air). These situations can be dangerous to your life.
If you find that the oxygen level in the air that you breathe is (or is likely to be) below
20.8%, this is indicative of poor ventilation or some other problem (see Table 2 and
Figure 3 for examples). Below 19% oxygen, the atmosphere is considered to be
oxygen-deficient. However, any deviation from 20.8%
Should be investigated and appropriate action taken.

3.43 Oxygen enrichment

In some processes and environments (eg oxy-gas welding), it is possible to have raised
levels of oxygen (more than 20.8%), which in turn lead to increased dangers of fire,
explosion or chemical reaction, making it more hazardous to work. In these cases you
should take appropriate action to ensure safe working. Never use pure oxygen to
‘sweeten’ an atmosphere (eg to rectify oxygen deficiency or ‘kill off’ unwanted
smells).
3.44 Confined spaces

A confined space is a substantially enclosed space such as a chamber, tank, vat, silo,
pit, trench, pipe, sewer, flue, well or small room with limited access and inadequate air
exchange. A confined space may not necessarily be enclosed on all sides. This space
can create a life-threatening situation due to:
1. a sudden release of high concentrations of hazardous substances; or
2. an oxygen deficiency due to the build-up of asphyxiants; or
3. the simple act of breathing.
All work in confined spaces must comply with the Confined Spaces Regulations.

3.45 Implementing RPE use in the workplace

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 For RPE to be effective over the short and long term it must be integrated into normal
workplace activities. You must ensure that control measures including RPE are
properly used and are not made less effective by bad work practices or by improper
use.

Your employees must use the control measures, including RPE, in the way they are
intended to be used and as trained and instructed by you. It is often best to give a
choice of several correctly specified types of RPE to wearers so they can choose the
one they like.

3.46 Designated areas

You may also want to designate areas where RPE is needed as ‘RPE zones’. This will
make it clear where RPE is required. You should note that designation of RPE zones is
mandatory if you have to comply with the CAW RPE use should fall within the
general health and safety framework in your workplace. A good introduction to
effective health and safety management is given in the HSE leaflet

3.47 Management and supervision

You should ensure that you or a person delegated by you is responsible for the
management and implementation of RPE use into your workplace. Ideally, the person
should be the line manager of the ‘hazardous processes. This person may be supported
by either internal or external safety professionals.

3.48 Training

All people involved in the selection, wearing, storage and maintenance (if required)
must be trained. The training programme should at least cover the following areas:
1. Why is RPE needed?
2. What are the hazards, the risks and the effects of exposure?
3. What RPE is being provided?
4. How does the RPE work?
5. Why fit testing is required (if relevant).
6. How do you wear and check it correctly?
7. Fit checking before use.
8. What maintenance is required and when?
9. Where and how do you clean and store it?
10. How do you report any problems?
11. Employee and employer responsibilities.
12. Use and misuse of RPE.
13. Your RPE supplier should provide information on the training required to use and
maintain their products. Anybody using or maintaining RPE should be competent.
You should be able to demonstrate this by reference to records of appropriate
training.
14. You may also want to raise awareness of health and safety issues by ensuring that

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 they are covered first at all team and management meetings.

3.49 Misuses of RPE

There have been serious accidents and fatalities due to incorrect selection or misuses of RPE.
The examples and case studies in this section give information and warning. Incorrect
selection and misuse invalidate the suitability of RPE and constitute a failure to comply with
the law. Health and safety inspectors seek to secure compliance with the law. If they find any
incorrect selection or misuse of RPE, including the examples given below, they will consider
enforcement action.

Different types of misuse of RPE are listed. Some examples are illustrated overleaf; many
other types of misuse exist.

3.50 Accidents involving RPE

You should report accidents involving RPE and diseases resulting from exposure to
hazardous substances by completing the appropriate online report form at
www.hse.gov.uk/riddor. You should consult L73 A guide to the Reporting of Injuries,
Diseases and Dangerous Occurrences Regulations 199510 for specific details.

4.1 Identification of Respiratory Hazards:

4.1.1 The safety data sheets for the chemicals in the workplace shall be used to
provide information on the health effects and hazards for those materials.

4.1.2 The respiratory hazards shall be identified through the exposure risk
assessment and workplace monitoring as per the SOP No. EHS/004.

4.2 Respirator selection:

4.1.3 All respirators have use limitations. There is not one all-purpose respirator.
The easiest way to review the uses and limitations of the respirator is to read
the respirator instructions that come with each respirator package.

4.1.4 Respirator selection shall be upon the physical and chemical properties of
the air contaminants and the concentration level likely to be encountered by
the employee.
4.1.5 The respirators shall be used in compliance with the conditions of its
certification. Respirators should be certified according to NIOSH or other
appropriate National or International Standards.

4.1.6 Different types of respirators (APR/ ASR, Tight-fitting/Loose fitting &

Positive pressure/ Negative pressure) and their Assigned Protection Factors
(APF) of various types of RPE is given in Appendix–2.

4.1.7 Fit testing shall be carried-out for all tight-fitting respirators. Requirement

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 of fit test for various respirators given in Appendix-2.

4.1.8 An Air-Purifying Respirator (APR) does not supply oxygen and therefore
cannot be used to enter an atmosphere that is oxygen deficient. APRs are
designed to protect the wearer for short periods ONLY.

4.1.9 An Atmosphere-Supplying Respirator (ASR) (i.e., Supplied-air and

SCBAs) must provide employees with compressed breathing air of high
purity. Air quality must meet or exceed the following requirements:

Type 1 - Grade D developed by ANSI/CGA G-7.1 - 2011

(adopted by OSHA under their respiratory standard 29
CFR, 1910.134)
S.No
Characteristics Limit
.
Percent Oxygen
01 19.5% - 23.5%
balance is predominantly nitrogen
02 Water, ppm (v/v) 67
03 Water, dew point °F at 1 atm abs (-) 50
3
04 Oil Components (mg/m ) 5
05 Carbon Monoxide (ppm) 10
06 Carbon Dioxide (ppm) 1000
07 Odor None

Breathing air quality specification for Air described in

IS: 15879: 2009
S.No
Characteristics Limit
.
Oxygen concentration by
01 21±1 percent
volume (dry air) (O2)
Shall not exceed 15ml/m3
02 Carbon Monoxide (CO)
(15ppm)
Shall not exceed 500ml/m3
03 Carbon Dioxide (CO2)
(500ppm)
- No free liquid water.
- 25ppm at package outlet for
filling cylinders.
- 50ppm at cylinder outlet
04 Water Vapor (H2O) (cylinder pressure 4MPa to
20MPa (g).
- 35ppm at cylinder outlet
(cylinder pressure >20MPa
(g).
05 Oil Components Shall not exceed 0.5mg/m3

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 (Condensed
(15ppm)
hydrocarbons)
Odor, flavor substances Free of any significant odor
06
and taste or taste.

Note: The test results shall meet any of the above standards.

4.3 Medical Evaluation:

4.1.10 The medical evaluation shall obtain the information as requested in the
questionnaire given in the Annex-1.

4.4 Respirator Fit Testing:

4.1.11 An employee using a tight-fitting face-piece respirator must be fit tested

(either qualitative or quantitative) 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.

4.1.12 EHS department shall ensure that employees using tight-fitting face piece
respirators are qualified (pass) in an appropriate qualitative fit test (QLFT)/
quantitative fit test (QNFT).

4.1.13 A detailed protocol on qualitative fit testing and the information on

qualitative fit test kit given in the Appendix-3.

4.1.14 Record the details of fit testing of each user as given in Annex-2.

4.5 Use of Respirators:

4.1.15 Respirators must be used properly to ensure the appropriate level of

respiratory protection is consistently achieved and maintained.

4.1.16 Donning, Doffing and User Seal Check: Refer Appendix-4.

4.1.17 Filter & Cartridges change schedule:

4.1.17.1 The useful life of respirator filters and cartridges shall be identified
for each type of respirator used. Replacement of respirator filters or
cartridges shall be based on objective information that will ensure that
all filters and cartridges are changed before the end of their service
life. Disposable respirators, respirator filters and respirator cartridges
shall be based on the most limiting factor below:
4.1.17.2 Disposable respirators:

 Prior to expiration date (if applicable).

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  At the end of each work shifts.
 Manufacturer’s recommendations for the specific use and
environment.
 When contaminant odor detected.
 When restriction to airflow has occurred as evidence by
increase effort by user to breathe normally.
 Respirators shall remain in their original sealed packages until
needed for immediate use.

4.1.17.3 Particulate filter and cartridge pre-filters:

 Prior to expiration date (if applicable).

 At the end of each work shifts.
 Manufacturer’s recommendations for the specific use and
environment.
 When contaminant odor detected.
 When restriction to airflow has occurred as evidence by
increase effort by user to breathe normally.
 Filters and cartridge pre-filters shall remain in their original
sealed packages until needed for immediate use.

4.1.17.4 Gas or Vapor Cartridges:

 Prior to expiration date (if applicable).

 After sixty (60) hours of use.
 Manufacturer’s recommendations for the specific use and
environment.
 When contaminant odor detected.
 When restriction to airflow has occurred as evidence by
increase effort by user to breathe normally.
 Gas or vapor cartridges shall remain in their original sealed
packages until needed for immediate use.
4.1.17.5 Filters or Cartridges for potent substances:

 Prior to expiration date (if applicable).

 Each time the respirator is cleaned or at the end of each shift,
whichever is sooner.
 Manufacturer’s recommendations for the specific use and
environment.
 When contaminant odor detected.
 When restriction to airflow has occurred as evidence by
increase effort by user to breathe normally.
 Filters and cartridges for potent substances shall remain in their
original sealed packages until needed for immediate use.

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 4.6 Maintenance and Care of Respirators:

4.1.18 Respirators must be clean, disinfected and properly stored. Respirator shall
be cleaned by the following steps and as given in Appendix-5.

4.1.19 Respirators Storage:

4.1.19.1 All respirators must be stored to protect them from damage,

contamination, dust, sunlight, extreme temperatures, excessive
moisture and chemicals.

4.1.19.2 They shall be packed or stored in such a manner as to prevent

deformation of the face-piece and exhalation valve.

4.1.20 Respirators Inspection:

4.1.20.1 The employee (user) must ensure that respirators are routinely
inspected. All respirators used in routine situations shall be inspected
before each use and during cleaning.

4.1.20.2 A check of respirator function, tightness of connections and

condition of various parts including but not limited to, the face-piece,
head straps, valves, connecting tube, and cartridges, canisters or
filters.

4.1.20.3 A check of elastic parts for pliability and signs of deterioration.

4.1.21 Respirators Repairs: If an employee determines that a respirator has

impairment or is deficient in some manner, the employee must notify their
supervisor and ensure that the unit is removed from service and is repaired or
discarded.

S. No. Hazards to be considered Recommended PPE with description PPE Image

Places where falling objects,
hitting objects (low ceiling,
Helmet (IS 2925): Hard hat with inner
1 beams) spills, electrical sparks,
cushion and chinstrap.
shocks and chemical splashes
may fall on the head.

Places where dust particles, Face shields: Transparent plastic

2 chemical splashes may fall over moulded glass screen with headband
the face facility

Places where spills, chemical Safety Glasses/ Spectacles:

3
splashes may fall into the eyes -0- power lens with side cover

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S. No. Hazards to be considered Recommended PPE with description PPE Image
Places where spills, chemical
Safety Goggles:
splashing liquid chemicals,
4 -0- power lens with full eye protection
fumes, vapor, powders, dusts and
with elastic band
mist may fall into the eyes

Places where noise is more than Earmuffs:

5 90 dB(A) for an 8-hour period of Enclosure to the ears with a headband
time facility. This can reduce 25 to 30 dB (A).

Ear plugs:
Places where noise is more than
Foam or PVC makes plug which can be
6 90 dB(A) for an 8-hour period of
inserted into the canal of the ears. This
time
can reduce 10 to 15 dB (A).

To wear while handling bases,

Rubber Hand Gloves
alcohols, dilute water solutions;
7 (Acid and Alkali Resistance):
fair vs. aldehydes, ketones.
Made out of PVC Rubber

To wear while handling, charging

Hand Gloves – PVC:
and transferring Strong acids and
8 Made out of PVC and cloth braided
bases, salts, other water solutions,
inside
alcohols.

To wear while handling pharma

activities like sifting, sieving, Hand Gloves (Surgical):
9
blending, packing and Made out of heavy duty rubber.
micronization.

To wear while handling Alcohols,

Bromides, Chlorides, Oxidizing
Hand Gloves (Neoprene):
10 acids, anilines, phenol, glycol
Made out of Neoprene rubber.
ethers.

To wear while handling and

transferring Oils, greases,
aliphatic chemicals, xylene, per
11 Hand Gloves (Nitrile)
chloro ethylene, tri chloro ethane;
fair vs. toluene.

To wear while handling high

12 33KV Electrical Gloves
voltage electrical works.

To wear Mechanical activities and

Cut Resistant Gloves
13 in the handling of sharp
objectives.

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S. No. Hazards to be considered
14 To hold the hot objects
Workplaces where dusts /
15 respirable particulate matter
present.
Workplaces where chemical
16
dusts/ fumes/ vapors present.
Places where chemical dust,
chemical powders, mists and
17
fumes may affect the respiratory
system and eyes of the persons
Places where chemical dust,
chemical powders, mists and
18
fumes may affect the respiratory
system of the persons
Places where chemical dust,
19 Chemical powders, mists, fumes
and vapor areas…
Places where chemical dust,
20 Chemical powders, mists, fumes
and vapor areas…
In case of emergency situations
like Toxic chemical fumes, fire
21 situations and the confined spaces
where oxygen availability is
below 16%
Places where chemicals may fall
22
over the body from trunk portion
Recommended PPE with description PPE Image
Heat/ Cold Resistant Gloves:
Nomex/ Kevlar gloves (or) Cotton
Nose Masks:
N95 Particulate Matter Dust masks
Nose masks:
Masks resistant to Organic/ Acid/
Ammonia/ Universal etc.
Face Masks (Full Face Masks):
Facemask with full vision PVC glass face
screen with headbands attached with
Dust filter cartridge or with Canister
cartridge.
Nose Mask (Half face Masks):
Half face masks with headbands, which
covers the nose in perfect manner with
single or dual cartridge type canisters or
with dust, filter cartridge
Supplied airline respiratory Mask:
Facemask with full vision PVC glass face
screen with headbands attached with air
regulator, waist belt and filter unit along
with air supply pipe.
Bubble Hood:
Hood covers complete head, made out of
transferent plastic sheet and having
provision to connect supplied air and an
exhalation valve.
Self-Contained Breathing Apparatus
(SCBA):
Face mask with full vision PVC glass
face screen with headbands attached with
air regulator, waist belt along with air
supply cylinder to cope up the 45 minutes
duration.
Apron – Chemical resistant:
Made out of PVC and Tyvek coated
Page 39 of 49
S. No. Hazards to be considered Recommended PPE with description PPE Image

Places where chemicals

Suits – Chemical resistant:
23 (solid/semisolid/liquids) may fall
Made out of PVC and Tyvek coated
over the body of the persons

Places where chemicals

(solid/semisolid/liquids) may fall Suits – Chemical resistant with airline
24 over the body of the persons. And supply provision:
protects from toxic fumes due to Made out of PVC and Tyvek coated
the supply airline facility

Delta Suits: Fully Encapsulating

Places where handling high potent
25 Ventilated Pressurized Suit
and highly toxic chemicals.

To wear while handling the fire Fire proximity suits:

prone chemicals like sodium Made out of special fire retardant cloth to
26
hydride, raney nickel and carbon resist heat up to 450 - 600 degrees
catalysts etc. centigrade.

To wear while dealing with Gum shoes:

27
chemicals handling PVC makes acid & alkali proof

Safety shoes:
To wear all time while working in Made out of leather and oil & acid
28
the premises resistant and antistatic sole with steel or
PP toe.
Full body harness:
To wear while working on heights
Fully adjustable shoulder, waist and
29 and in the vessels / confined
thigh straps made out of wear resistant
spaces
nylon webbing

4.7 Non-Respiratory PPE must be cleaned, dried and stored properly as follows.
Type of
S. No. Non-RPE Image Cleaning Procedure
Non-Respiratory PPE
1. Disconnect the helmet refill & sweat band.
2. Immerse the refill & sweat band with water.
3. Wipe the helmet with wet cloth.
1 Safety Helmet
4. Rinse the helmet, refill & sweat band thoroughly in
running water.
5. Hand-dry with another dry cloth or air dry.

1. Disconnect the face shield from helmet.

2. Wipe the face shield with wet cloth.
2 Face Shields 3. Rinse the face shield thoroughly in running water.
4. Hand-dry with another dry cloth or air dry.
5. Keep it in its place for using.

1. Wipe the spectacles/ glasses with wet cloth.

2. Rinse the spectacles/ glasses thoroughly in running
Safety Glasses/ Spectacles
3 water.
3. Hand-dry with another dry cloth or air dry.
4. Keep it in its place for using.

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 Type of
S. No. Non-RPE Image Cleaning Procedure
Non-Respiratory PPE

1. Wipe the earmuffs with wet cloth.

2. Hand-dry with another dry cloth or air dry.
4 Earmuffs/ Plugs
3. Keep it in its place for using.
4. Discard the ear plugs after use.

Hand Gloves 1. Immerse the gloves with water.

(Related to chemicals like 2. Wipe the gloves with wet cloth.
5
nitrile/ neoprene PVC/ 3. Rinse the gloves thoroughly in running water.
surgical/ rubber etc… 4. Hand-dry with another dry cloth or air dry.

1. Wipe the hand gloves with wet cloth.

33KV Electrical Hand 2. Rinse the gloves thoroughly in running water.
6
Gloves 3. Air-dry the electrical gloves.
4. Keep it in its place for using.

1. Immerse the apron with water.

2. Wipe the apron with wet cloth.
7 Body Apron
3. Rinse the apron thoroughly in running water.
4. Hand-dry with another dry cloth or air dry.

1. Immerse the suit (Hood, Shirt & Pant) with water.

Suits - Chemical resistant 2. Wipe the suit with wet cloth.
8
(Hood, Shirt & Pant) 3. Rinse the suit thoroughly in running water.
4. Hand-dry with another dry cloth or air dry.

1. Immerse the suit (pant & shirt) with water.

Fire proximity suit 2. Wipe the suit with wet cloth.
9
3. Rinse the suit thoroughly in running water.
4. Air dries the suit.
1. Immerse the gum shoes with water.
Gum shoes 2. Wipe the gum shoes with wet cloth.
10
3. Rinse the gum shoes thoroughly in running water.
4. Hand-dry with another dry cloth or air dry.

Recommended
S. No. Hazards to be considered RPE Image Fitting Type Fit test
RPE
Atmosphere-Supplying Respirators

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 Recommended
S. No. Hazards to be considered RPE Image Fitting Type Fit test
RPE
Supplied airline
respiratory Mask:
Facemask with full
vision PVC glass,
Places where chemical dust,
face screen with Tight- Positive
1 Chemical powders, mists, Required
headbands attached fitting Pressure
fumes and vapor areas…
with air regulator,
waist belt and filter
unit along with air
supply pipe.

Hood: Hood
covers complete
head, made out of
Places where chemical dust, transferring plastic Not
Loose- Positive
2 Chemical powders, mists, sheet and having
fitting Pressure
fumes and vapor areas… provision to Required
connect supplied
air and an
exhalation valve.

Inhalation of chemical Full Body Suit:

Not
contaminants along with Loose- Positive
3
splash hazard on the body Made out of PVC fitting Pressure Required
(solid/semisolid/liquids) and Tyvek

Delta Suits: Fully

Encapsulating
Places where handling high Not
Ventilated Loose- Positive
4 potent and highly toxic
Pressurized Suit fitting Pressure
chemicals. Required

SCBA: Face mask

with full vision
PVC glass face
In case of emergency
screen with
situations like Toxic chemical
headbands attached Demand/
fumes, fire situations and the Tight-
5 with air regulator, Pressure Required
confined spaces where fitting
waist belt along Demand
oxygen availability is below
with air supply
16%
cylinder to cope up
the 45minutes
duration.

Air-Purifying Respirators

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 Recommended
S. No. Hazards to be considered RPE Image Fitting Type Fit test
RPE
Disposable Masks:
Workplaces where Particulate With Particulate Tight- Negative
6 Matter/ Organic/ Acid/ Required
Matter/ Organic/ fitting Pressure
Ammonia etc… present. Acid/ Ammonia/
Universal filters

Half face Masks

with

Workplaces where Particulate Cartridges or

Tight- Negative
7 Matter/ Organic/ Acid/ Canisters for Required
fitting Pressure
Ammonia etc… present. Particulate Matter/
Organic/ Acid/
Ammonia/
Universal etc.

Full Face Masks

with

Workplaces where Particulate Cartridges or

Tight- Negative
8 Matter/ Organic/ Acid/ Canisters for Required
fitting Pressure
Ammonia etc… present. Particulate Matter/
Organic/ Acid/
Ammonia/
Universal etc…

Powered Air
purifying
Protection against high Respirators
Not
concentrations of dusts/ mists (PAPR): Battery/ Loose- Positive
9
etc… suitable where there is rechargeable fitting Pressure Required
no supplied air provision. filtration unit is
attached to face
mask/hood.

Assigned Protection Factors *

Loose-
Quarter Half Full face
S. No. Type of Respirator Helmet hood fitting
mask mask piece
face-piece
1 Air-purifying Respirator 5 10 $ 50 --- ---
Powered Air-purifying
2 --- 50 1000 25/1000 # 25
Respirator (PAPR)
Supplied-air Respirator (SAR) or Airline Respirator
 Demand mode --- 10 50 --- ---
3  Continuous flow mode --- 50 1000 --- ---
 Pressure-demand or other
--- 50 1000 25/1000 # 25
positive-pressure mode

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 Self-contained Breathing Apparatus (SCBA)
 Demand mode --- 10 50 50 ---
4  Pressure-demand or other
positive-pressure mode --- --- 10,000 10,000 ---
(e.g., open/closed circuit)

DISPOSABLE RESPIRATOR
DONNING DOFFING
Ste Description with Pictogram Step Description with Pictogram
p

1 1
Cup the respirator in your hand with the nose
piece at fingertips, allowing the head straps
to hang freely below hand. Without touching the respirator, slowly lift
Position the respirator under your chin with the bottom strap from around your neck up
the nose piece up. and over your head.

2 2

While holding the respirator in place, pull the

top strap over your head so it rests high on Lift off the top strap. Do not touch the
the back of your head. respirator.

3 3
While continuing to hold the respirator
firmly in place, pull the bottom strap over
your head and position it around your neck, Store or discard according to your facility’s
below your ears. Untwist the straps. Position disposal policy.
the respirator low on your nose.

4
Using both hands, mold the nose piece to the
shape of your nose by pushing inward while
moving your fingertips down both sides of
the nose piece.

Page 44 of 49
 Name of the Work Area Visitors
Engg. & Maint.
Protection Pharma Offices
Laboratories
Required Manufacturing/ & Utilities
(R&D, PD, Warehouse (Admin,
Kilo Lab Finished and DG Sets and
QC etc…) QA)
Goods Boiler Compressors
areas
Head
√ √ √ √ √
(Helmet)
Face & Eyes
(Safety √ √ √ √ √ √ √ √
Glasses)
Ear (Muffs/
√ √ √ √
Plugs)
Hands
(Gloves)
(When √ √ √ √ √ √ √
Attempting
work)
Feet (Safety
√ √ √ √ √ √ √
Shoes)
Body
√ √ √ √ √ √
(Apron)

Note:
Employees, whichever it may be their department while they are entering into above areas must
wear the applicable PPE as mentioned above.
1. Other PPE is recommended to use when they are carrying specific works.
2. PPE applicability to Visitors as per site implementations.

4.8 Observations and Conclusions:

Observations
All the workman’s to know the donning procedure of
RPE
If the RPE is fit to workman’s
If the any storage of PPE at workplace is available
If the any cleaning procedure are available for the
Reusable RPE
Misusing of Nitrogen instead of Breathing Air
Conclusions
80% of workman’s to know the donning procedure of
RPE
To aware the workman’s on concept of RPE usage
procedure by class room training and PEP Talks
To test the workman’s by using RPE fit test and give
the suitable RPE
PPE are stored in dedicated PPE box in workplace
Cleaning procedure for the Reusable RPE
 Disconnect all removable parts
 Wash components with plenty of water
 Rinse components thoroughly in running water
 Hand-dry with clean lint free cloth or air dry
 Reassemble all the components of RPE
To minimizing of Asphyxiation hazard below

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 procedures are followed
 Warning sign board
 Asphyxiation hazard  Color coding of pipe line
 Fatal hazard  Class room training
 Mismatching of nozzle to be arranged to nitrogen
and breathing air.
5.0 Definitions:

5.1 Employee exposure means exposure to a concentration of an airborne contaminant

that would occur if the employee not using respiratory protection.

5.2 Respirator: A respirator is a protective device that covers the nose and mouth or the
entire face or head to guard the wearer against hazardous atmospheres.

5.3 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.

5.4 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.

5.5 Tight-fitting respirator: A respirator, which cover the mouth and nose (half mask)
and full face pieces that cover the face that forms a complete seal with the face. 

5.6 Loose-fitting respirator: Respirator such as hood or helmet that cover the head
completely.

5.7 Negative pressure respirator: A respirator in which air pressure inside the face piece
is negative during inhalation with respect to the ambient air pressure outside the
respirator.

5.8 Positive Pressure Respirator: A respirator in which the pressure inside the face
piece exceeds the ambient air pressure outside the respirator.

5.9 Demand respirator means an atmosphere-supplying respirator that admits breathing

air to the face-piece only when a negative pressure is created inside the face piece by
inhalation.

5.10 Pressure demand respirator means a positive pressure atmosphere-supplying

respirator that admits breathing air to the face-piece when the positive pressure is
reduced inside the face-piece by inhalation.

5.11 Filtering face-piece (dust mask) means a negative pressure particulate respirator

with a filter as an integral part of the face-piece or with the entire face-piece
composed of the filtering medium.

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5.12 Filter or air purifying element: A component used in respirators to remove solid or
liquid aerosols from the inspired air.

5.13 High efficiency particulate air (HEPA) filter means a filter that is at least 99.97%
efficient in removing mono-disperse particles of 0.3 micrometers in diameter. 

5.14 Respirator Canister or cartridge: A container with a filter, sorbent, or catalyst, or

combination of these items, which removes specific contaminants from the air passed
through the container.

5.15 Supplied-air respirator (SAR) or airline respirator means an atmosphere-

supplying respirator for which the source of breathing air is not designed to be
carried by the user.

5.16 Powered air-purifying respirator (PAPR): An air-purifying respirator that uses a

blower to force the ambient air through air-purifying elements to the inlet covering.

5.17 Self-contained breathing apparatus (SCBA): An atmosphere-supplying respirator

for which the breathing air source is designed to be carried by the user.

5.18 Escape-only respirator: A respirator intended to be used only for emergency exit.

5.19 Full-Face Respirator: A face piece that covers from roughly the hairline to below
the chin. On average they provide the greatest protection, usually seal most reliably,
and provide some eye protection.

5.20 Half-Face Respirator: A face piece that fits over the nose and under the chin and
does not protect the eyes.

5.21 Respiratory inlet covering: A portion of a respirator that forms the protective barrier
between the user's respiratory tract and an air-purifying device or breathing air
source, or both. It may be a face-piece, helmet, hood, suit, or a mouthpiece respirator
with nose clamp.
5.22 Helmet: A rigid respiratory inlet covering that also provides head protection against
impact and penetration.

5.23 Hood: A respiratory inlet covering that completely covers the head and neck and may
also cover portions of the shoulders and torso. 

5.24 Assigned Protection Factor (APF): Assigned Protection Factor means the minimum
expected workplace level of respiratory protection provided by a properly
functioning respirator. The respirator selected must have an assigned protection
factor adequate for the particular workplace exposure.

Divide the air contaminant concentration by the occupational exposure limit (OEL)
to obtain a hazard ratio. Then select a respirator with an assigned protection factor

Page 47 of 49
 greater than or equal to that hazard ratio.

Hazard Ratio = Airborne Contaminant Concentration / OEL

5.25 User Seal Check: An action conducted by the respirator user to determine if the
respirator is properly seated to the face.

5.26 Fit test: A method to qualitatively or quantitatively evaluate the fit of a respirator on
an individual.

5.27 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. 

5.28 Quantitative fit test (QNFT): An assessment of the adequacy of respirator fit by
numerically measuring the amount of leakage into the respirator.

5.29 Fit Factor: A quantitative estimates 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.

5.30 Service life: The period of time that a respirator, filter or sorbent or other respiratory
equipment provides adequate protection to the wearer.

5.31 Occupational Health Representative: Medical attendant working in Occupational

Health Centre under the guidance of factory medical officer.
5.32 Emergency situation: Any occurrence such as, but not limited to, equipment failure,
rupture of containers, or failure of control equipment that may or does result in an
uncontrolled significant release of an airborne contaminant.

5.33 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.

5.34 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.

5.35 Oxygen deficient atmosphere: An atmosphere with oxygen content below 19.5% by
volume.

5.36 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, and is determined by the assigned protection factor of the
respirator or class of respirators and the exposure limit of the hazardous substance.
MUC = APF x OEL

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 5.37 Occupational Exposure Limit (OEL): OEL is an upper limit on the acceptable
concentration of a hazardous substance in workplace air.

5.38 Threshold Limit Value (TLV): The threshold limit value of a chemical substance is
a level to which it is believed a worker can be exposed day after day for a working
life time without adverse effects.
3.0 References
1. Personal protective equipment at work. Personal Protective Equipment at Work
Regulations 1992. Guidance on Regulations HSE Books 2005
www.hse.gov.uk/pubns/books
2. Safety Manuals
3. Respiratory protective equipment Guidelines.

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