HSE-SAF-STD-00-0063

SAFETY
Rev. 6
06-Aug-2016
RESPIRATORY PROTECTION STANDARD
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TABLE OF CONTENTS

1. INTRODUCTION........................................................................................................... 2

2. SCOPE & PURPOSE ................................................................................................... 2

3. DEFINITIONS ............................................................................................................... 2

4. STANDARD .................................................................................................................. 4

5. RESPONSIBILTIES .................................................................................................... 12

6. REFERENCES ............................................................................................................ 14

7. ATTACHMENTS ......................................................................................................... 14

8. APPENDICES ............................................................................................................. 14

9. REVISION HISTORY .................................................................................................. 24

Rev. Issue Date Amendment Description Prepared By Reviewed By Approved By

 Periodic Revision
 Document category changed from ‘PLN’ to
‘STD’. The doc. HSE-SAF-PLN-00-0004 is
superseded.
 Revised respirator selection section into the
respirator approval and selection. Added
requirements. (Section 4.2.1)
 Added respirator selection requirement in
Section 4.2.2.
 Included reference of respirator wearers fitness Sara M Khamis/
evaluation procedure. (Section 4.4) Abdul W Sheikh/
 Added respirators maintenance requirement for Joel A Marmolejo/ Carl Poldrack/
use in emergency situation, fit testing and Jonathan Roehl
training. Saucedo/ Bartolome/
5 06-Aug-16 Amit Parikh Mahesh Dirk Perrin/
 Added breathing air quality testing standard
Parameshwaran/ Abdulla S Al-
reference in the section 4.9.
Rajagopal S Zoubi/
 Added “medical signs and symptoms that may Kumar/
limit or prevent the effective use of respirators” Sanjay Bhatt/
and retraining requirement in section 4.10. Boppana Saibabu/
 Included annually program review in section Mary Green/
4.13.
 Added responsibilities on supervisor and end
users in Section 5.
 Revised Attachment 8 and included Attachment
9 & 10.
 Added Appendix IV and Tables 1, 2 & 3.
 Included ‘Respirator Selection Criteria - Nature
of Hazard’ (Appendix IV -Sec III)
Next Scheduled Periodic Review: August/2019

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1. INTRODUCTION

This standard outlines the establishment and maintenance of effective respiratory protection
program when employees must wear respirators to protect against workplace hazards.
Q-Chem will first attempt to determine the feasibility of using engineering control measures to
control atmospheric contaminants. These controls shall include enclosure or confinement of the
operation, general and local ventilation, and/or the substitution of less toxic materials.
Respiratory protective equipment shall be utilized whenever engineering or administrative
controls are not feasible; while engineering controls are being installed; when engineering
controls are not working properly or during the repair of these controls.
This program is intended to comply with OSHA 29 CFR 1910.134: Respiratory Protection
Standard.

2. SCOPE & PURPOSE

The purpose of this program is to protect against health hazards caused by breathing air
contaminated with harmful dusts, fogs, fumes, mists, gases, smokes, sprays, and/or vapours.
This standard is applicable to all employees and contractors entering the Q-Chem Plant
premises that are required to wear respirators during normal work operations and during some
non-routine or emergency operations. Respirators must be provided by Q-Chem when such
equipment is necessary to protect the health of the employee or contractor. Q-Chem must
provide respirators that are applicable and suitable for the purpose intended. Q-Chem in this
document refers to Q-Chem, Q-Chem II and RLOC operating facilities.
Contractors, other than Q-Chem base load contractor, are exempt from the medical surveillance
component, but are still required to complete the Respiratory questionnaire before completing
the fit test.

3. DEFINITIONS

 Air-purifying Respirator - means a respirator with an air-purifying filter, cartridge, or

canister that removes specific air contaminants by passing ambient air through the air-
purifying element.
 Atmosphere-supplying Respirator - means a respirator that supplies the respirator user
with breathing air from a source independent of the ambient atmosphere, and includes
supplied-air respirators (SAR’s) and self-contained breathing apparatus (SCBA) units.
 Batch/Lot - refers to breathing air cylinders filled in one operational run, typically defined as
(1) day by OSHA.
 Breathing Air - is air provided to a worker via a supplied airline or self-contained tank
meeting OSHA Type 1 – Grade D specifications.
 Breathing Air Room - An area set up in the fire station where respiratory equipment is
serviced and maintained. Serviced full & half face piece masks are available for trade in
with masks that have been used in the field.
 Canister or Cartridge - means a container with a filter, sorbent, or catalyst, or combination
of these items, which removes specific contaminants from the air passed through the
container.
 Certificate of Analysis (COA) - is a guarantee by the manufacturer of breathing air that
the air in the breathing air cylinders meets the OSHA Type 1 – Grade D specifications. The

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certificate gives the assurance that the breathing air being used by employees is safe.
Hence, a certificate MUST be provided for each lot of cylinders produced.
 Emergency Situation - means 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.
 Employee Exposure - means exposure to a concentration of an airborne contaminant that
would occur if the employee were not using respiratory protection.
 Escape-only Respirator - means a respirator intended to be used only for emergency exit.
Being clean shaven is not a pre-requisite for using this type of respirator as their purpose is
solely for the rapid egress from a potentially hazardous environment.
 Filter or air Purifying Element - means a component used in respirators to remove solid
or liquid aerosols from the inhaled air.
 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.
 Fit Factor - means a quantitative estimate of the fit of a particular respirator to a specific
individual, and typically estimates the ratio of the concentration of a substance in ambient
air to its concentration inside the respirator when worn.
 Fit test - means the use of a protocol to qualitatively or quantitatively evaluate the fit of a
respirator on an individual.
 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. The
equivalent NIOSH 42 CFR 84 particulate filters are the N100, R100, and P100 filters.
 Immediately Dangerous to Life or Health (IDLH) - means 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.
 Negative pressure Respirator (Tight fitting) - means a respirator in which the air
pressure inside the face piece is negative during inhalation with respect to the ambient air
pressure outside the respirator.
 Oxygen deficient atmosphere - means an atmosphere with oxygen content below 19.5%
by volume.
 Positive pressure Respirator - means a respirator in which the pressure inside the
respiratory inlet covering exceeds the ambient air pressure outside the respirator.
 Quantitative Fit Test (QNFT) - means an assessment of the adequacy of respirator fit by
numerically measuring the amount of leakage into the respirator.
 Qualitative Fit Test (QLFT) - means the respirator user conducts a pre-use respirator seal
check to ensure no leakage of the face piece.
 Respirator Mask Storage Cabinet - A wooden shelf designed to accommodate respirator
masks.
SCOTT AV-2000 SCOTT AV-3000
 Red – Extra Large (XL)  Red dot on inside seal of mask – Large (L)
 Black – Large (L)  Black dot on inside seal of mask – Medium (M)
 Green – Small (S)  Green dot on inside seal of mask – Small (S)
 Self-contained Breathing Apparatus (SCBA) - means an atmosphere-supplying
respirator for which the breathing air source is designed to be carried by the user.

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 Service life - means the period of time that a respirator, filter or absorbent, or other
respiratory equipment provides adequate protection to the wearer.
 Similar Exposure Groups (SEGs) - A group of employees who likely experience similar
exposure to chemical or physical agents. The exposure must be similar enough so that
monitoring a randomly selected group of workers in the SEG provides data which can be
used to predict the exposure of the general population of workers in the SEG.
 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.
When a SAR is used in an IDLH condition, the individual must also carry an Escape Pack
for the safe egress in case of disruption in the air supply.
 SCOTT AV-2000 - means site approved full face piece masks that can be used both as a
respirator when fitted with a V-Bar adapter and cartridges or as a SCBA mask when fitted
with a regulator.
 SCOTT AV-3000 - means site approved full face piece masks that can be used both as a
respirator when fitted with a V-Bar adapter and cartridges or as a SCBA mask when fitted
with a regulator.
 Scott Series Canisters or Cartridges - means canisters / cartridges that are designed to
provide protection in non-Immediately Dangerous to Life & Health (IDLH) or HAZMAT
situations. Canisters/cartridges are stored by the user but acquired from the material
warehouse through stocked min/max PPE items.
 Tight-fitting Face piece - means a respiratory inlet covering that forms a complete seal
with the face.
 User Seal Check - means an action conducted by the respirator user to determine if the
respirator is properly seated to the face.
 V-Bar Adaptor - is an adaptor mechanism that fastens the canister filtration elements to
the SCOTT AV-2000 or AV-3000 face piece/mask.

4. STANDARD

4.1. Program Administrator

i. The Industrial Hygienist shall oversee, maintain, and evaluate the program’s effectiveness.
ii. The Industrial Hygienists for each site location (Mesaieed and Ras Laffan) shall be
appointed to fulfil these duties for the Company.

4.2. Respirator Approval and Selection

4.2.1. Approval

i. All respiratory equipment used at Q-Chem shall be authorized by the Safety

Department.
ii. Only those employees included in this program (Refer Table I in Appendix IV) may
perform tasks that require the use of a respirator. Employees who are not included in
the program who need to wear a respirator shall contact the IH/Safety Department and
request inclusion in the program based on Hazard Assessment.
iii. Visitors and contractors shall be required to comply with the Q-Chem Respiratory
Protection Standard when the task is one for which respiratory protection required.

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4.2.2. Selection

i. Respiratory protection is mandatory when performing work in areas where the

concentration of airborne pollutants are at or above the Action Level (with the exception
of Hydrogen Sulfide, H2S – see attached Respirator Selection Table HSE-SAF-TBL-00-
0001) and where employee exposure cannot be identified or reasonably estimated.
a) Action Level is equal to 50% or ½ of the Occupational Exposure Limit, OEL (see
attached OEL Table HSE-SAF-TBL-00-0002).
b) Where employee exposure cannot be identified or reasonably estimated the exposure
shall be considered to be IDLH.
ii. Specific respirator selection for the common and specific tasks based on the hazard
assessment and evaluation shall be referred in Appendix IV.
iii. Specific respirator for the any new task or job classification shall be evaluated by the Q-
Chem IH Section/Safety department (Respirator Selection Worksheet - HSE-SAF-SFM-
00-0166).
iv. Q-Chem makes use of the following NIOSH certified re-usable respirators and
employees can select respirators from a sufficient number of respirator models and sizes
so that the respirator is acceptable to, and fits correctly. All Q-Chem respirators meet
protection factors listed in Table II.
a) Scott Aviation AV 2000
b) Scott Weld-O-Vista Welding Fume Respirator
c) Scott Aviation AV 3000
d) Scott Aviation Model 66 (XCEL)
e) MSA OPTIMAIR 3000 Powered Air-Purifying Respirators [Mesaieed only]

NOTE 1

These face pieces have a variety of canisters that may be worn with them;
hence, the canisters and face pieces are packaged separately. At the time
of issue the appropriate canister is determined, based on the user’s
needs.

v. In addition, the following disposable respirators are also available:

a) N-95 general purpose respirator mask
b) FFP2 welding fume respirator mask

NOTE 2

Do not use a respirator mask if is not stored in a sealed bag. The only
exception to this is the same person using the mask multiple times in one
shift.

vi. Employees shall use only atmosphere supplying respirator and air purifying respirator
equipped with an end-of-service-life indicator (ESLI) or in case of no ESLI appropriate for
conditions shall follow a change schedule for canisters and cartridges (Refer Respirator
Selection Table - HSE-SAF-TBL-00-0001).

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NOTE 3

Air purifying canisters are to be replaced at any time if an individual

detects any kind of odour while wearing the respirator mask or if breathing
becomes difficult.

4.3. Medical Screening

i. The Health Services Department, under the guidance of QP Occupational Health Physician,
will initially, and periodically thereafter, make a determination as to whether or not an
employee can wear the required respirator without physical or psychological risk. Details
can be found in Respirator Wearers Fitness Evaluation Procedure (AD-MED-PRO-00-
0001).
ii. In cases where an employee is not deemed fit to wear the required respirator, the
employee, his/her supervisor, and the Industrial Hygienist shall be formally notified of the
restriction.
iii. Specific medical tests and procedures will be determined by Q-Chem Senior Health
Practitioner in accordance with QP Occupational Health Physician.

NOTE 4

Voluntary use of a respirator

Employees using respirators when not required under this program shall
read Appendix II – “Information for Employees Using Respirators When
Not Required Under the Standard”.

4.4. Fit Testing

i. Employees requiring use of any of the Q-Chem approved respirator with a negative or
positive pressure tight-fitting face piece, must be fit tested with the same make, model, style
and size of respirator that will be used.(See Appendix III: Fit Testing Procedure)
ii. Employees are required to complete a Respirator Wearers Medical Evaluation Questionnaire
(AD-MED-SFM-00-0004) and obtain clearance from Health Services prior to undertaking
each annual fit test.
iii. The employees using a tight-fitting face piece respirator shall pass the quantitative fit test
before wearing a respirator.
a) Voluntary use of a respirator: A fit test is not required for voluntary users or for escape-
only respirators.
iv. No fit testing will be performed on an employee who has facial hair which comes between
the sealing periphery of the face piece and the face, or if facial hair interferes with normal
functioning of the exhalation valve of the respirator. ( Refer Q-Chem Facial Hair Policies
(HSE-HGN-PCY-00-0009)
v. No respirator user is permitted to wear a respirator in a designated respirator work area
until he or she has demonstrated that an acceptable fit can be obtained, i.e. passed the
necessary qualitative (pre-use in field) and quantitative fit tests.
vi. Respirator fit testing shall be conducted at the following frequency / intervals:

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a) Initially upon assignment to a task requiring use of a respirator.

b) Annual re-testing (upon successful completion of the respirator training).
c) Whenever a different respirator face piece (size, style, model or make) is used.
d) If a change in the employee's physical condition could affect the respirator fit.
vii. If the respirator subsequently becomes unacceptable (i.e., causes irritation or pain to the
employee), the employee shall be given the opportunity to select a different respirator face
piece and be retested.
viii. Quantitative fit testing will be conducted by Industrial Hygienist or Technician and/or Fire
Technician and the test results will be the determining factor in selecting the size of
respirator for use by each individual respirator wearer. End user shall get a prior
appointment for fit test through e-mail or calendar booking.
ix. The user will perform qualitative fit checks each time a respirator is donned (see Appendix I
for details).
a) These checks are not a substitute for quantitative fit testing.
b) Respirators users shall be properly trained in the performance of these checks and
understand their limitations.

4.5. Use of Respirators

Employees using Q-Chem approved respirator shall fulfil below requirements:

i. The employees shall not don respirators with tight-fitting face pieces under below
conditions:
a) Facial hair that comes between the sealing surface of the face piece and the face or that
interferes with valve function.
b) Any condition that interferes with the face-to-face piece seal or valve function.
Examples could include:
 Stubble beard growth
 Beard
 Sideburns which cross the respirator sealing surface
ii. If an employee wears corrective glasses he/she shall ensure that such equipment is worn in
a manner that does not interfere with the seal of the face piece by using proper respirator
insert. Prescriptions insert for Scott or equivalent face pieces shall be reviewed by the
Safety Department or withdraw from the warehouse. To qualify for a prescription insert it
must be shown that the employee performs regular-routine work in a full-face air supplied or
air purifying respirator.
iii. Employees shall perform a seal check each time when they wear respirator.
iv. Employees shall stop the use of respirator under any abnormal changes in work condition
such as unusual odour or abnormal reading through portable direct reading monitor and
seek advice from his/her Supervisor and Industrial Hygienist.
v. Use under IDLH condition.
In general no work shall be carried out under IDLH atmosphere (Refer section 4.7.(iv)
of Confined Space Entry Procedure, HSE-SAF-PRO-00-0007).

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vi. Air purifying canisters or cartridges are not to be shared. Once an individual has finished
using the canisters or cartridges, they are to be discarded in the appropriate waste
container which has been provided and marked as per Environmental Waste Management
Plan.
a) Cartridges used for hexavalent chromium activities will be:
 Respirators shall be worn while in the "Dirty" room of a decontamination facility, until
showering (unless inadvertent contamination has occurred and a respirator was not
being worn at the time of the inadvertent exposure)
vii. A set of air purifying canisters are not to be used for more than one shift by any one
individual. Replace the canisters after a 12 hour shift as a minimum (See Attached
Respirator Selection Table HSE-SAF-TBL-00-0001 for canister/cartridge replacement
cycles).

4.6. Maintenance, Inspection & Care of Respiratory Protective Equipment

i. The Fire Section will ensure that sufficient full face piece masks are available for issue at
any time:
a) Only those persons trained and authorized may disassemble and repair breathing air
equipment; this includes all full face piece masks.
ii. The maintenance and inspection of respiratory protective devices shall include:
a) A thorough visual inspection for cleanliness and defects (i.e., cracking rubber,
deterioration of straps, defective exhalation and inhalation valves, broken or cracked
lenses, etc.).
b) Worn or deteriorated parts will be replaced by a certified technician prior to reissue.
c) No respirator with a known defect is reissued for use.
d) No attempt is made to replace components, make adjustments or make repairs on any
respirator beyond those recommended by the manufacturer.
e) Under no circumstances will parts be substituted as such substitutions will invalidate the
approval of the respirator.
iii. All respirators maintained for use in emergency situation shall be inspected at least monthly
(Refer Equipment Management Standard, HSE-ERT-STD-00-0008).
iv. Certify the respirator by documenting the date the inspection was performed, the name (or
signature) of the person who made the inspection, the findings, required remedial action,
and a serial number or other means of identifying the inspected respirator.
v. Provide this information on a tag or label that is attached to the storage compartment for the
respirator, is kept with the respirator, or is included in inspection reports stored as paper or
electronic files. This information shall be maintained until replaced following a subsequent
certification.
a) Emergency escape only respirator shall be inspected before being carried into the
workplace for use.
b) All respirators used in routine situations shall be inspected before each use and during
cleaning.
vi. Any repair to reducing or admission valves, regulators, or alarms shall be conducted by
either the manufacturer or a qualified trained technician.

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vii. Respirators shall be cleaned and sanitized after each use (Refer Respiratory Washer/Dryer
Procedure - HSE-ERT-PRO-00-0025).
a) Replacement cartridges/ canisters are stored by the
b) user but acquired from the material warehouse through stocked min/max PPE items.
viii. Cleaning and disinfection of respirators must be done frequently to ensure that skin-
penetrating and dermatitis-causing contaminants are removed from the respirator surface.
a) Respirators maintained for emergency use or those used by more than one person shall
be cleaned and disinfected after each use by the user.
b) Respirators used in fit testing and training shall be cleaned by using respirator cleaning
wipe after each use.
ix. Respirators will be cleaned and disinfected by the Fire Technicians following the OSHA
approved respirator cleaning procedure.
NOTE 5
All respirators used in routine situations shall be inspected before
each use by the end user.

4.7. Storage of Respirators

i. Respirator mask cabinets have been installed in the following areas:

MESAIEED
Sulfur FIC Ethylene FIC
North Off Site Catalyst Activator Building
Product Warehouse NAO
Maintenance Polyethylene Train III
South Off Site Train III - Catalyst Activator Building
Polyethylene FIC 1-Hexene FIC
Incinerator FIC Fire Station
Central Control Room Q-Chem II - Central Control Room
RAS LAFFAN
Central Control Room Fire Station

Note: The mask cabinet or any of its individual storage compartments shall not to be used
for anything but the storage of respirator masks in sealed bags. Used masks shall not be
returned to the mask cabinet compartments.
ii. After repairing (made by a certified technician), inspecting and cleaning the respirators shall
be wrapped in plastic bags and sealed to protect against the environment, moisture, dust
,chemicals or any other contaminants.
iii. Respirators shall be packed or stored so that the face piece and exhalation valves will rest
in a normal position and not be crushed.
iv. Respirators placed at stations and work areas for emergency use shall be stored in
compartments built for that purpose shall be quickly accessible at all times and will be
clearly marked.

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NOTE 6
Respirators shall not be stored or placed under sunlight or extreme
temperatures.

4.8. Breathing Air Quality

i. Compressed breathing air shall meet at least the requirements for Type1 – Grade D
breathing air as per OSHA 29 CFR 1910.134 (i). Details can be found in Breathing Air
Quality Testing Standard (HSE-SAF-STD-00-0023).

4.9. Training

i. Q-Chem respirator users will receive training on the contents of the Respiratory Protection
Program (RPP) and their responsibilities under it.
ii. RPP training is conducted annually via computer based modules & instructor-led sessions
(practical implications) and will include:
a) Q-Chem Respiratory Protection Program
b) Nature and degree of respiratory hazards
c) Respirator selection, based on the hazard and respirator capabilities and limitations
d) Donning procedures, check the seals of the respirator and fit tests; including hands-on
practice (qualitative fit testing)
e) Care of the respirators, e.g., need for inspection, cleaning, maintenance, storage, and/or
replacement
f) Use and limitations of respirators
g) Medical signs and symptoms that may limit or prevent the effective use of respirators
iii. Q-Chem respirator users completing the classroom training must then schedule themselves
for fit testing and prove competence in donning a respirator.
iv. For Contractors, the Designated Site Representative (DSR) must ensure training is
provided to respirator users prior to being assigned duties requiring the use of respirators.
a) The Training Department must coordinate classroom respirator training as required.
b) Retraining (contractors) shall be conducted annually through instructor-led / classroom
sessions coordinated by the Training Coach.
v. The Training Department shall retain all training records for all Q-Chem-approved respirator
users.
vi. The Industrial Hygiene section maintains current fit testing records for all respirator users.
vii. Retraining shall be conducted in case changes in the workplace or the type of respirator
render or inadequacies in the employee's knowledge, use or any other situation arises in
which re-training appears necessary to ensure safe respirator use.

4.10. Program Evaluation

i. The Industrial Hygienist must audit the Respirator program every three years, which
includes the following (Refer Respiratory Protection Program Review Checklist – HSE-SAF-
SFM-00-0123):

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a) Investigating wearer acceptance of respirators

b) Inspecting respirator program operation
c) Appraising protection provided by the respirator
d) Cleaning and disinfecting procedure – Fire Station
ii. The findings of the respirator program evaluation will be documented and include the
following:
a) Plans to correct faults in the program
b) Target dates for the implementation of the plans

4.11. Record Keeping

i. Respirator fit-testing will be documented (Fit testing database located with Industrial
Hygienist) and include the following:
a) Type of respirator
b) Brand name and model
c) Method of test, test results and test date
d) Name of the instructor/tester

4.12. Program Review

i. Program reviews shall be conducted at least annually, with time between reviews not to
exceed twelve months.
ii. The program reviews shall be conducted by the site Industrial Hygienist using the
Respiratory Protection Program Review Checklist (HSE-SAF-SFM-00-0123).
iii. Random interviews with employees shall be conducted periodically (annual) to determine
employees’ views on the effectiveness of the program and to identify problems (Respirator
Protection Program Employee Interview Checklist - HSE-SAF-SFM-00-0167).
iv. The Respiratory Protection Standard (HSE-SAF-STD-00-0063) shall be reviewed and
revised under the following conditions:
a) Every three (3) years, with time between reviews not to exceed thirty six months.
b) If required by the outcomes of the annual program reviews.
c) A change review team (CRT) comprising of affected stakeholder shall be formed to
conduct the standard reviews.
v. The following items shall be addressed during the standard review process:
a) Records of any incidents or near misses involving toxicant exposure
b) Lesson learned reports from other CPChem affiliate facilities
c) Any audit findings from the previous thirty six months period
d) Legislation changes in the OSHA 29 CFR 1910.134: Respiratory Protection Standard.

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5. RESPONSIBILTIES

5.1. Industrial Hygienist

i. Acts as the respiratory protection program administrator.

ii. Provide consultation on the selection and use of respirators.
iii. Recommends the appropriate respirators and associated equipment for purchasing when
determined necessary or warranted.
iv. Manages the respiratory protection program and facilitates the three yearly reviews.
v. Conducts periodic (Annual review) audits to determine the effectiveness of the respiratory
protection program.
vi. Provide quantitative fit testing and training on the use of respirators.
vii. Maintain fit testing database of all users.
viii. Issue fit test validation card or sticker.

5.2. Fire Section

i. Assist Industrial Hygiene Section with quantitative fit testing and training on the use of
respirators.
ii. Properly clean, maintain, care for and inspect all respirators prior to issuing to end-users.
iii. Certify the respirator by documenting the date the inspection was performed, the name (or
signature) of the person who made the inspection, the findings, required remedial action
and a serial number or other means of identifying the inspected respirator.
iv. Ensure all breathing air used on Q-Chem sites meet OSHA Type 1 – Grade D
specifications and that the analysis documentation is provided by the supplier/vendor.
v. Inspect and act as approval authority for breathing air systems (compressors and / or
cascade systems) brought onto the Q-Chem site by contractors/vendors (Refer Breathing
Air Quality Report Form - HSE-SAF-SFM-00-0058).
vi. Only issue respiratory protective equipment to person’s with a valid fit test card or sticker
(check expiry date on card or sticker).

5.3. Department Managers

i. Ensure that all affected personnel follow this program.

ii. Where feasible implement workplace (engineering or other) controls to eliminate the need
for the use of respirators.

5.4. Supervisors/Designated Site Representative (DSR)

i. Identify work operations and personnel that may require the use of respirators and forward
information onto Health Services, Training & Industrial Hygienist for training & fit-testing
respectively.
ii. Ensure that employees wearing respirators follow the respiratory protection program.
iii. Ensure that only those employees who have a valid fit test are allowed to wear respirators.

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iv. Notify the IH Section/Safety Department of changes in work practices or new job activities,
which may require changes or additions to the program.
v. Ensure that employees are provided adequate time away from their duties for compliance
with fit testing, training, and care and maintenance aspects of the program.

5.5. Health Services

i. Provide medical surveillance for Q-Chem direct hire, seconded employees and contractor
who are required to wear a respirator.
ii. Provide Medical Screening, using the Respirator questionnaire, to all persons required to
wear a respirator.

5.6. End Users

i. Adhere to the requirements of the respiratory protection program.

ii. Complete all safety training, quantitative fit testing, and medical surveillance requirements
and comply with documentation procedures.
iii. Complete qualitative fit testing (pre-use).
iv. Follow guidelines on the proper use and limitations of respiratory protection.
v. Shall report to their supervisor any changes in personal (e.g., physical or mental conditions)
or job (e.g., work environment) factors which might preclude their wearing of a respirator.
This includes medical problems associated with the facial hair requirement.
vi. Shall participate in medical evaluations or exams deemed necessary by the Q-Chem Health
Services
vii. Shall comply with the facial hair requirements of the program.
viii. Return used masks immediately to fire station after use.
ix. Do not drop off masks to the fire station without fire station personnel being present.
x. Do not remove any masks from the fire station without the knowledge of fire station
personnel.
xi. Return new stock back to the respirator mask storage cabinet.
xii. Ensure the plastic bags containing the masks are sealed properly.
xiii. Respirators used in hexavalent chromium activities will go through proper local
decontamination and flushing prior to drop off and exchange at the fire station.
xiv. Notify Fire Section of any equipment problems etc.
xv. Keep the mask cabinet and compartments free of any dust or other debris.

5.7. Training Section

i. Provide training on the use of respirators.

ii. Issue Safety Training Report for Contractors prior to Fit Testing appointment.

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6. REFERENCES

6.1. Occupational Safety and Health Administration’s (OSHA) Respiratory Protection Standard –
29 CFR 1910.134
6.2. OSHA 29 CFR 1910.134 Appendix B-1: User Seal Check Procedures (Mandatory)
6.3. OSHA 29 CFR 1910.134 Appendix B-2: Respirator Cleaning Procedures (Mandatory)
6.4. OSHA 29 CFR 1910.134 Appendix A : Fit Testing Procedure (Mandatory)
6.5. Q-Chem Facial Hair Policy - HSE-HGN-PCY-00-0009
6.6. Respirator Wearers Fitness Evaluation Procedure - AD-MED-PRO-00-0001
6.7. Respiratory Washer/Dryer Procedure - HSE-ERT-PRO-00-0025
6.8. Breathing Air Quality Testing Standard - HSE-SAF-STD-00-0023
6.9. Breathing Air Quality Report Form - HSE-SAF-SFM-00-0058
6.10. Respiratory Protection Program - HSE-SAF-PPT-00-0063
6.11. Respiratory Protection – Refresher - HSE-SAF-CBT-00-0040

7. ATTACHMENTS

7.1. Respirator Selection Table - HSE-SAF-TBL-00-0001

7.2. Occupational Exposure Limits (OEL) Table - HSE-SAF-TBL-00-0002
7.3. Respiratory Protection Program Review Checklist - HSE-SAF-SFM-00-0123
7.4. Respirator Selection Worksheet - HSE-SAF-SFM-00-0166
7.5. Respirator Protection Program Employee Interview Checklist - HSE-SAF-SFM-00-0167

8. APPENDICES

8.1. Appendix I - Negative and Positive Pressure Checks

8.2. Appendix II - Information for Employees Using Respirators When Not Required Under
The Standard
8.3. Appendix III - Fit Testing Procedure
8.4. Appendix IV - Respirator Selection Guide

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Appendix I
NEGATIVE AND POSITIVE PRESSURE CHECKS

1. Negative Pressure Check

1.1. Applicability/Limitations
This test cannot be carried out on all respirators; however, it can be used on face pieces of
air purifying respirators equipped with tight-fitting respirator inlet covers and on atmosphere
supplying respirators equipped with breathing tubes which can be squeezed or blocked at
the inlet to prevent the passage of air.

1.2. Procedure
Close off the inlet opening of the respirator's canister(s), cartridge(s), or filter(s) with the palm
of the hand, or squeeze the breathing air tube or block its inlet so that it will not allow the
passage of air. Inhale gently and hold for at least 10 seconds. If the face piece collapses
slightly and no inward leakage of air into the face piece is detected, it can be reasonably
assumed that the respirator has been properly positioned and the exhalation valve and face
piece are not leaking.

2. Positive Pressure Check

2.1. Applicability/Limitations
This test cannot be carried out on all respirators; however, respirators equipped with
exhalation valves can be tested.

2.2. Procedure
Close off the exhalation valve or the breathing tube with the palm of the hand. Exhale gently.
If the respirator has been properly positioned, a slight positive pressure will build up inside
the face piece without detection of any outward air leak between the sealing surface of the
face piece and the face.
Appendix II
INFORMATION FOR EMPLOYEES USING RESPIRATORS
WHEN NOT REQUIRED UNDER THE STANDARD

Respirators are an effective method of protection against designated hazards when properly
selected and worn. Respirator use is encouraged, even when exposures are below the
exposure limit, to provide an additional level of comfort and protection for workers. However,
if a respirator is used improperly or not kept clean, the respirator itself can become a hazard
to the worker. Sometimes, workers may wear respirators to avoid exposures to hazards,
even if the amount of hazardous substance does not exceed the limits set by OSHA
standards. If your employer provides respirators for your voluntary use, or if you provide your
own respirator, you need to take certain precautions to be sure that the respirator itself does
not present a hazard.

You should do the following:

i. Ensure you are clean shaven before using any respirator; even disposable masks.
ii. Read and heed all instructions provided by the manufacturer on use, maintenance, cleaning
and care, and warnings regarding the respirators limitations.

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iii. Choose respirators certified for use to protect against the contaminant of concern. NIOSH,
the National Institute for Occupational Safety and Health of the U.S. Department of Health
and Human Services, certifies respirators. A label or statement of certification should
appear on the respirator or respirator packaging. It will tell you what the respirator is
designed for and how much it will protect you.
iv. Do not wear your respirator into atmospheres containing contaminants for which your
respirator is not designed to protect against. For example, a respirator designed to filter
dust particles will not protect you against gases, vapours, or very small solid particles of
fumes or smoke.
v. Keep track of your respirator so that you do not mistakenly use someone else's respirator.

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Appendix III
FIT TESTING PROCEDURE

Fit testing is an important requirement in the process of determining whether a given

respirator is the “correct” respirator for a particular worker. Fit testing helps determine that a
particular model and size of respirator fits a worker so there is minimal face seal leakage.
Employees required to wear a tight fitting respirator must be fitted properly and tested for
face seal leakage before using the respirator in a contaminated area. To determine whether
the respirator provides an adequate face seal, the respirator wearer is quantitative fit tested
while performing exercises such as normal and deep breathing, moving the head side to side
or up and down, bending at the waist and talking. One of the OSHA recommended
quantitative fit testing procedure is accepted by Q-Chem, it provides a numerical result (a fit
factor), and this number appears to indicate the best respirator fit.

The ambient aerosol condensation nuclei counter (CNC) quantitative fit testing (Portacount
TM
) protocol quantitatively fit tests respirators with the use of probe attachments (TSI
sampling adapters) that permit fit testing in an employee's own respirator. A minimum fit
factor pass level of at least 500 is required for a full face piece negative pressure respirator.
The entire screening and testing procedure shall be explained to the test subject prior to the
conduct of the screening test. The test will be performed as per OSHA-accepted quantitative
fit test protocols.

The following requirements apply to all the employees for the QLFT and QNFT.

i. The employees are allowed to pick the most acceptable respirator from a sufficient number
of respirator models and sizes so that the respirator is acceptable to, and correctly fits, the
user.
ii. Prior to the selection process, the employees are train on how to put on a respirator, how it
should be positioned on the face, how to set strap tension and how to determine an
acceptable fit. A mirror shall be available to assist the subject in evaluating the fit and
positioning of the respirator.
iii. The test subject shall be informed that he/she is being asked to select the respirator that
provides the most acceptable fit. Each respirator represents a different size and shape, and
if fitted and used properly, will provide adequate protection.
iv. The test subject shall be instructed to hold each chosen face piece up to the face and
eliminate those that obviously do not give an acceptable fit.
v. The more acceptable face pieces should be noted and the most comfortable mask is
donned and worn at least five minutes to assess comfort.
vi. The test subject shall conduct a user seal check, either the negative and positive pressure
seal checks described in Appendix I.
vii. The test shall not be conducted if there is any hair growth between the skin and the face
piece sealing surface, such as stubble beard growth, beard, moustache or sideburns which
cross the respirator sealing surface. Any type of apparel which interferes with a satisfactory
fit shall be altered or removed.
viii. If a test subject exhibits difficulty in breathing during the tests, she or he shall be referred to
a health care professional, as appropriate, to determine whether the test subject can wear a
respirator while performing her or his duties.

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ix. If the employee finds the fit of the respirator unacceptable, the test subject shall be given
the opportunity to select a different respirator and to be retested.
x. Exercise regimen. Prior to the commencement of the fit test, the test subject shall be given
a description of the fit test and the test subject's responsibilities during the test procedure.
The description of the process shall include a description of the test exercises that the
subject will be performing. The respirator to be tested shall be worn for at least 5 minutes
before the start of the fit test.
xi. The fit test shall be performed while the test subject is wearing any applicable safety
equipment that may be worn during actual respirator use which could interfere with
respirator fit.
xii. Employees perform the test exercises in the appropriate test environment in the following
manner:
a) Normal breathing. In a normal standing position, without talking, the subject shall breathe
normally.
b) Deep breathing. In a normal standing position, the subject shall breathe slowly and
deeply, taking caution so as not to hyperventilate.
c) Turning head side to side. Standing in place, the subject shall slowly turn his/her head
from side to side between the extreme positions on each side. The head shall be held at
each extreme momentarily so the subject can inhale at each side.
d) Moving head up and down. Standing in place, the subject shall slowly move his/her head
up and down. The subject shall be instructed to inhale in the up position (i.e., when
looking toward the ceiling).
e) Talking. The subject shall talk out loud slowly and loud enough so as to be heard clearly
by the test conductor. The subject can read from a prepared text such as the Rainbow
Passage, count backward from 100, or recite a memorized poem or song.
f) Grimace. The test subject shall grimace by smiling or frowning.
g) Bending over. The test subject shall bend at the waist as if he/she were to touch his/her
toes. Jogging in place shall be substituted for this exercise in those test environments
such as shroud type QNFT or QLFT units that do not permit bending over at the waist.
h) Normal breathing. Same as exercise (a).
xiii. Each test exercise shall be performed for one minute except for the grimace exercise which
shall be performed for 15 seconds. The test subject shall be questioned by the test
conductor regarding the comfort of the respirator upon completion of the protocol. If it has
become unacceptable, another model of respirator shall be tried. The respirator shall not be
adjusted once the fit test exercises begin. Any adjustment voids the test, and the fit test
must be repeated.

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Appendix IV

Respirator Selection Guide

Section I - Purpose

The purpose of this guide is to aid in the proper selection of a respirator for specific task. Refer
section 2 and 3 of the PPE Matrix of Q-Chem (HSE-SAF-TBL-00-0008) and RLOC (HSE-SAF-
TBL-30-0002) for the common task and task specific to select respirator. Contact to IH
section/safety department for specific respirator for the any new task or job classification.

Refer below Section II and select the respirator and accessories (chemical cartridge, filter, pre-
filter, retainer) for the job/task.

If a guide is not provided for the task you are going to perform and you believe that respiratory
protection may be needed for the job, contact to IH section/safety department. Upon completion of
a job assessment, new guides will be added to the “Respirator Selection Guide”.

Section II – Respirator Guides

R1

Airborne Particulates Respirator

Respirator 3M 8210, N 95 particulate respirator and 3M

9925/ 8214 Premium welding respirators
with ozone protection./ /Equivalent approved
by Safety Section.

R2

Airborne Particulates Respirator

Respirator Half Face (Scott Xcel) with P-100 Particulate
cartridge/Equivalent approved by Safety
Section.

R3

Airborne Organic Vapor with High Efficiency Particulates Air Filter Respirator
Respirator Half Face (Scott Xcel) with Organic Vapor &
P-100 combo cartridge//Equivalent approved
by Safety Section.

R4

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Airborne Particulates Respirator

Full Face (Scott AV2000/3000) with P-100
Respirator cartridge/Equivalent approved by Safety
Section.

R5

Airborne Organic Vapour/Acid Gases//Ammonia/Formaldehyde/ Particulates Respirator

Full Face (Scott AV2000/3000) with
Respirator Multipurpose /P-100 cartridge/Equivalent
approved by Safety Section.

R6

Airborne Organic Vapor/Acid Gas with High Efficiency Particulates Air Filter Respirator
Full Face (Scott AV2000/3000) with Organic
Respirator Vapor/Acid Gas & P-100 Combo
Cartridge/Equivalent approved by Safety
Section.

R7

Self-Contained Breathing Apparatus,pressure demand type,full

face piece 10,15,30 and 60 Minutes Respirator
Full Face (Scott AV2000/3000) with
Respirator minimum air quality of Grade-D as per the
Breathing Air Quality Testing Standard
(HSE-SAF-STD-00-0023) /Equivalent
approved by Safety Section.

R8

Airline Pressure Demand type with Full Face Piece Respirator

Full Face (Scott AV2000/3000) with
Respirator minimum air quality of Grade-D as per the
Breathing Air Quality Testing Standard
(HSE-SAF-STD-00-0023) /Equivalent
approved by Safety Section.

R9

Airborne Mercury Vapor/Chlorine with High Efficiency Particulates Air Filter Respirator

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Full Face (Scott AV2000/3000) with Mercury

Respirator Vapor/Chlorine & P-100 Combo Cartridge
/Equivalent approved by Safety Section.

R10

Supplied Air Abrasive Blasting Hood or Helmet Respirator

Airline continuous flow to hood or helmet
Respirator with minimum air quality of Grade-D as per
the Breathing Air Quality Testing Standard
(HSE-SAF-STD-00-0023)

R11

Airborne Welding Fumes Respirator

Weld-O-Vista with welding visor with P-100
Respirator cartridge/supplied air and SCBA
applications.

Note:
1. Refer approved PPE and Safety Equipment List for the standards & specification of the
respirators.
2. Contact safety section for the clarification or the approval for the equivalent respirator or
relevant accessories.

Section III – Respirator Selection Criteria - Nature of Hazard

Respirator selection is based on physical, physiological, and situational factors in the work
environment. Factors influencing respirator selection include:

i. An environment that is Immediately Dangerous to Life or Health (IDLH). An IDLH

atmosphere is any atmosphere that poses an immediate hazard to life or produces
immediate irreversible effects on health. This normally is due to an oxygen deficiency or the
concentration of a toxic contaminant(s).
ii. Oxygen deficient atmosphere: an atmosphere is considered oxygen deficient whenever the
concentration of oxygen is less than 19.5%
iii. Physical and chemical properties of the contaminant, concentration (average and peak), and
warning properties.
iv. Operation and work area characteristics, materials (raw materials, end products, byproducts,
etc.), and worker activities.
v. The location of the hazardous area with respect to a safe area having respirable air can
influence the respirator selection.
vi. Whether the work rate is light, medium, or heavy and whether it is intermittent or continuous.

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vii. The period of time the respirator will be worn and the application (emergency, routine, non-
routine, etc.).
viii. The physical characteristics, functional capabilities, and performance limitations of the
respirator.

Table I

Employees Included in the Respiratory Protection Program

SEGs Code Similar Exposure Groups (SEGs)

QC-ETU-SRU-01-PO Process Operators & Technical Helpers - Ethylene & Sulfur

QC-ETU-02-SS Shift Supervisors - Ethylene & Sulfur
QC-PEU-HEX-01-PO Process Operators & Technical Helpers - Polyethylene & Hexene
QC-PEU-02-SS Shift Supervisors - Polyethylene & Hexene
QC-UTL-01-PO Process Operators & Technical Helpers - Utilities
QC-UTL-02-SS Shift Supervisors – Utilities
QC-MNT-01-WBF Welders & Fabricators
QC-MNT-05-MT.1 Mechanical Technicians, Pipe Fitter, Senior Mech. Tech - Ethylene & Sulfur
QC-MNT-05-MT.2 Mechanical Technicians, Pipe Fitter, Senior Mech. Tech, RET- Polyethylene &
Hexene
QC-MNT-05-MT.3 Mechanical Technicians Pipe Fitter, Senior Mech. Tech, RET- Utilities
QC-MNT-05-MT.5 Mechanical Technicians Pipe Fitter, Senior Mech. Tech, RET - Polyethylene
Train 3
QC-MNT-05-MT.6 Mechanical Technicians, Pipe Fitter - Logistics & Tank Farm
QCII-MNT-05-MT.4 Mechanical Techni
cians Pipe Fitter, Senior Mech.
QCII-PEU3-01-PO Process Operators & Technical Helpers - Polyethylene Train 3
QCII-PEU3-02-SS Shift Supervisors - Polyethylene Train 3
QC-LGN-06-DO Dock Operator
QC-HSE-02-FD Fire Tech. & FSC
QC-HSE-01-SAF. Industrial Hygiene / Safety Technician & Industrial Hygiene Specialist.
RLOC-ETU-01-PO Process Operators - ISBL
RLOC-ETU-02-SS Shift Supervisors - ISBL
RLOC-HSE-01-SAF Safety Support Staff - HSE Department
RLOC-MNT-01-WL Welders
RLOC-MNT-02-FA Fabricators
RLOC-MNT-10-RT Rotating Equipment Technicians - Maintenance

*NOTE:
1. DSR shall evaluate requirement of respirator for the contractor based hazard assessment
for the specific task/activity.
2. Employees using respiratory equipment must be sure they have the proper type of
respirator for the exposure that will be encountered.
3. An employee may be required to use any respirator with a negative or positive pressure
tight –fitting face piece for the any new task which is not documented in hazard assessment
and PPE matrix shall be evaluated by the Q-Chem Safety Department (HSE-SAF-SFM-00-
0166).

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Table II

Protection Factors for the Respirators

Quarter Mask Permitted for Use Protection

in IDLH Factor
Atmosphere
Type of Respirator
Air-Purifying Respirator Yes No 10
Airline demand-type full face Yes No 50
piece
Airline pressure demand-type Yes No (1) 1000
with full face piece
Airline continuous flow full Yes No 50
face piece
Airline continuous flow hood Yes No 25
or helmet
Self-contained breathing Yes No 50
apparatus, open-circuit,
demand-type, full face piece
Self-contained breathing Yes Yes 10,000
apparatus, open-circuit,
pressure demand-type, full
face piece

Notes:
1. Employees may select respirators assigned for use in higher workplace concentrations of a
hazardous substance for use at lower concentrations of that substance, or when required
respirator use is independent of concentration.
2. The assigned protection factors in above table are only effective when the employee shall
gone through training, fit testing, maintenance, and use requirements.
3. This APF category includes filtering face pieces, and half masks with elastomeric face
pieces.
4. Contractor shall provide protection factor for the respirator planned to use from the
manufacturer for the approval of safety department.
5. These APFs do not apply to respirators used solely for escape.

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9. REVISION HISTORY

Rev. Issue Date Amendment Description Prepared By Reviewed By Approved By

 Added Program Administrator. (Section
4.1)
 Added requirement of fit test and fit testing
procedure in appendix 3 includes sufficient
number of respirator models and sizes.
(Section 4.4.(i))
 Use of respirator under IDLH condition and
non IDLH atmosphere. (Section 4.5)
 Added respirator repairing made by a
5 25-Jun-13 certified technician (Section 4.7.(ii)) Amit Parikh Lloyd Askham Carl Poldrack
 Added RPP training is conducted annually.
(Section 4.9.(ii))
 Added attachment 8 for the respiratory
protection program audit checklist in
program evaluation. ( Section 4.10)
 Added program review requirement
(Section 4.12)
 Added Attachments 6 & 7 and Appendix 3.
 Three year review plus inclusion of Fire &
Safety Coordinator (FSC) responsibility for
checking and approving breathing air Lloyd
4 01 -May-10 Jarvis Olsen
systems brought onto the Q-Chem sites by Askham
contractors or vendors using Attachment 5
(also new inclusion into program).
 Scott AV 3000 respirators were purchased
for RLOC. QII will utilize the existing Scott
AV 2000, which QCHEM is presently
utilizing.
 Respirator size recognition for RLOC was Lloyd
3 01-May-08 included into the definitions. Jarvis Olsen
Askham
 Addition of locations and number of
respirator cabinets in each facility.
 Revised Respirator Evaluation
Questionnaire.
 Inclusion of breathing air quality Lloyd
2 01-May-07 Jarvis Olsen
requirements Askham
Lloyd
1 01-Jan-06  Completely re-written from Rev 0 Jarvis Olsen
Askham

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