2. Respiratory Protection Program Overview
Eltaneice Bolden
Hao Xu
Bob Chapman

3. Objectives of This Course
Introduction
Objectives of This Course
Understand the elements of an effective program
Understand the roles and responsibilities of various personnel
Understand how to determine if respirator use can be considered voluntary and the requirements of voluntary respirators
Understand how to evaluate a program’s effectiveness

4. Standard Audit Performance Standard 3.4-190 – Respiratory Protection
Introduction
Standard
Audit Performance Standard – Respiratory Protection
Published in 2016, on JAS website

5. When must you wear a respirator?
Introduction
When must you wear a respirator?
Effective engineering control is not in place
Potential for overexposure
Difficult to measure or assess the exposure

6. When must you wear a respirator?
Introduction
When must you wear a respirator?
Oxygen deficient atmosphere (air supply only) Risk of IDLH exposure Respirator Program Coordinator determines one is required
IDLH picture

7. Qualitative vs. Quantitative
Exposure Assessment
Qualitative vs. Quantitative
Qualitative Exposure Assessment
Risk = Exposure Rate X Toxicity of a chemical
Quantitative Exposure Assessment
Based on breathing zone air sampling measurements

8. Exposure Assessment
Quantitative

9. Exposure Assessment
Qualitative

10. Hierarchy of Controls Exposure Assessment
Before using respirators, make sure that other controls are not practical. A respirator (PPE) is the last layer of defense!

11. Why Respirators Are the Last Choice?
Exposure Assessment
Why Respirators Are the Last Choice?
If not used properly, they may not offer the required protection They can be hot, uncomfortable and make it hard to see or communicate

12. Why Respirators Are the Last Choice?
Exposure Assessment
Why Respirators Are the Last Choice?
It can be hard to breathe if they are negative pressure respirators
They are easily removed in contaminated air

13. Respirator Selection
Seek Advice!
Talk to your industrial hygienist or your on-site Industrial Hygiene Technician to help select the right respiratory protection for the task.

14. Any questions? Contact your regional Industrial Hygienist.
Respirator Selection
Which Respirator?
Immediately Dangerous to Life and Health (IDLH): An atmospheric concentration of any toxic, corrosive or asphyxiant substance that poses an immediate threat to life or would cause irreversible or delayed adverse health effects or would interfere with an individual's ability to escape from a dangerous atmosphere.
Any questions? Contact your regional Industrial Hygienist.

15. Self-Contained Breathing Apparatus (SCBA)
Respirator Expo
Respirator Expo
Self-Contained Breathing Apparatus (SCBA)
Clean air delivered inside the mask
Used in Confined Space Entry/rescue
Good for Oxygen Deficiency, IDLH, chemicals with low OELs
Note: For emergency use only!

16. SCBA Limitations Respirator Expo
Use limited by amount of air in cylinder Weight & bulk decrease flexibility and mobility Face piece can limit visibility May limit hearing
May affect ability to communicate Increases air consumption Increases body temperature

17. Air Line Respirator Clean air delivered inside the mask
Respirator Expo
Air Line Respirator
Clean air delivered inside the mask
Used in Paint shop painting processes
Good for chemicals with low OELs
Can be used in oxygen deficient and IDLH environments w/escape SCBA

18. Air Line Respirator Limitations
Respirator Expo
Air Line Respirator Limitations
Loss of source air eliminates all protection to the user Hose affects maneuverability and may easily tangle or crimp. Face piece can limit visibility May limit hearing
May affect ability to communicate

19. Air-Purifying Respirator (APR)
Respirator Expo
Air-Purifying Respirator (APR)
Filtered air drawn in by inhaling Filter choice can be tailored to the contaminant Not for oxygen deficient environment Good for exposures above OEL

20. Air-Purifying Respirator Limitations
Respirator Expo
Air-Purifying Respirator Limitations
Do not protect against oxygen-deficient atmospheres and IDLH Cartridges must be changed periodically Must choose the right cartridge for the contaminant of concern Will not provide adequate protection: In confined spaces, in major leak/spill events or for certain highly toxic chemicals.

21. Powered Air Purifying Respirator (PAPR)
Respirator Expo
Powered Air Purifying Respirator (PAPR)
Filtered Air delivered to the mask Positive Pressure inside mask Filter Choice Can Be Tailored to the Contaminant Not for Oxygen Deficient Environments Good for exposures above OEL

22. PAPR Limitations Respirator Expo
Not evaluated for use in flammable or explosive atmospheres
Added weight/bulk decrease flexibility & mobility
Face piece can limit visibility
May affect ability to hear/communicate
Not for oxygen-deficient & IDLH atmospheres

23. Respirator Expo
Filter Cartridges
Contaminant-specific cartridges Cartridges for vapors and for particulates Stackable (particulate pre-filter + cartridge filter) Need to consider cartridge life & maximum filter efficiency in high exposure areas & must establish a change schedule

24. Sample Filter Cartridge Selection Chart
Respirator Expo
Sample Filter Cartridge Selection Chart

25. Respirator Expo
Filtering Face Piece
For dusts and mists below OEL NO protection from Vapor or Gas Different ratings for filter efficiency and oil resistance (N, R, P) Valves improve breathing efficiency Good for exposures < 10% of the OEL

26. Filtering Face Piece Limitations
Respirator Expo
Filtering Face Piece Limitations
Difficult to establish a good face seal
Difficult to check whether the face seal is adequate

27. Filtering Face Piece with Charcoal
Respirator Expo
Filtering Face Piece with Charcoal
Similar to filtering face piece for dust/mist Charcoal layer traps nuisance organic vapors Not used at or above Action Level Good for exposures below OEL

28. Filtering Face Piece with Charcoal Limitations
Respirator Expo
Filtering Face Piece with Charcoal Limitations
Difficult to establish a good face seal
Difficult to check whether the face seal is adequate.

29. Dust Mask Filtration Efficiency
Respirator Expo
Dust Mask Filtration Efficiency
Type
Filtration Efficiency of airborne particles
Resistance to Oil
N95
95%
Not resistant
N99
99%
N100
99.97%
R95
Somewhat resistant
P95
Strongly resistant
P99
P100

30. Program Requirements
Voluntary Use
Sometimes workers want to wear respirators even when no exposure over the action level is detected.
This is acceptable when…

31. Voluntary Use Program Requirements
When air sampling demonstrates the potential for overexposure as compared to the action level or an oxygen deficiency is unlikely
When workers have been informed of the risks and limitations of the using of filtering face-pieces and other respirators.

32. Voluntary Use – OSHA Requirements 1910.134(c)(2)
Program Requirements
Voluntary Use – OSHA Requirements (c)(2)
Only provide voluntary respirator when employer determines that use will not in itself create a hazard Employer shall provide Appendix D: “Information for Employees Using Respirators When Not Required Under the Standard”

33. Voluntary Use – OSHA Requirements 1910.134(c)(2)
Program Requirements
Voluntary Use – OSHA Requirements (c)(2)
Written Program
Employer must establish and implement a written respiratory protection program necessary to ensure that any employee using a respirator voluntarily is medically able to use that respirator, and that the respirator is cleaned, stored, and maintained so that its use does not present a health hazard to the user.

34. Voluntary Use – OSHA Requirements 1910.134(c)(2)
Program Requirements
Voluntary Use – OSHA Requirements (c)(2)
Exception:
Employers are not required to include in a written respiratory protection program those employees whose only use of respirators involves the voluntary use of filtering face pieces (dust masks).

35. Voluntary Use – GM Requirements
Program Requirements
Voluntary Use – GM Requirements
Must establish and implement a written respiratory protection program
The following conditions must be met:

36. Voluntary Use – GM Requirements
Program Requirements
Voluntary Use – GM Requirements
Medical evaluation has determined the worker is physically capable of wearing a respirator Respirator must be cleaned, stored, & maintained so that its use does not present a health hazard to the user Training must be conducted for the voluntary use of half- or full face piece respirators and PAPRs

37. Voluntary Use – GM Requirements
Program Requirements
Voluntary Use – GM Requirements
Voluntary use filtering face-pieces (e.g. efficiency-rated respirators such as N95s) and unrated masks (e.g. surgical mask, pollen mask) do not require a medical clearance evaluation Note: GM does not issue surgical masks for non-medical related use, nor does GM issue pollen masks for any use

38. Voluntary Use – GM Requirements
Program Requirements
Voluntary Use – GM Requirements
Filtering Face Piece Respirators e.g., N95, R95, P95 Provide Appendix D of OSHA Standard
Non-rated masks e.g., Pollen mask, surgical mask No OSHA respirator program requirements
Respirators
Not Respirators

39. Voluntary Use – Examples @ GM
Program Requirements
Voluntary Use – GM
Do you have any voluntary use respirators at your facility?

40. Medical Evaluation Program Requirements
Conducted before issuing respirator to worker To ensure worker is physically able to wear the respirator Required to obtain a fit test Exception: filtering face pieces with and without an efficiency rating (e.g. N95s, surgical masks, pollen masks
Note: surgical and pollen masks are not issued for use outside of Health Services activities.

41. Medical Surveillance Exam
Program Requirements
Medical Surveillance Exam
Performed annually to determine if the respirator wearer has experienced any adverse health effects Workers wearing voluntary use respirators are not included in medical surveillance

42. Medical Evaluation vs Medical Surveillance
Program Requirements
Medical Evaluation vs Medical Surveillance
Medical Evaluation
Medical Surveillance Exam
VS.
To ensure that people are physically able to wear the respirator
Annual exam to check ongoing suitability for respirator use

43. Roles and Responsibilities
Program Requirements
Roles and Responsibilities
Respirator Program Coordinator (RPC)
A designated, qualified person ultimately responsible for administering the respiratory protection program on site
Must have sufficient knowledge in respiratory protection through at least attending a basic respiratory protection class
Must have overall authority to coordinate all aspects of the program

44. Roles and Responsibilities
Program Requirements
Roles and Responsibilities
Respirator Program Coordinator (RPC)
Possesses knowledge of respirator selection, use, and maintenance
Develops & implements facility respirator operating procedures
Coordinates the following activities that involve respirators:
Purchasing Distribution Program Evaluation
Maintenance Fit Testing
Cleaning Training

45. Roles and Responsibilities
Program Requirements
Roles and Responsibilities
Safety and Industrial Hygiene
Support Respirator Program Coordinator
Assist in selection of appropriate respirators
Conduct exposure assessments (IH) to determine need for respirator use

46. Roles and Responsibilities
Program Requirements
Roles and Responsibilities
Health Services (Medical)
Perform respirator medical evaluations and annual medical surveillance exams
Determine when respirator cannot besafely worn by a worker

47. Roles and Responsibilities
Program Requirements
Roles and Responsibilities
Respirator User
Wear respirator according to instruction received in training
Report respirator damage to Supervisor or RPC
Replace cartridges/filters according to established schedule or when resistance increases or odor is detected, whichever comes first

48. Roles and Responsibilities
Program Requirements
Roles and Responsibilities
Respirator User
Maintain and store respirator according to instruction received in training
Report any health effects related to respirator use to site Medical

49. Respirator Selection – Assigned Protection Factors
Program Requirements
Respirator Selection – Assigned Protection Factors
Type of Respirator
Quarter Mask
Half Mask
Full Face piece
Helmet/ Hood
Loose-fitting Face piece
Air-Purifying Respirator 5 10 50 -
Powered Air-Purifying Respirator (PAPR)
1,000
25/1,000 25
Supplied-Air Respirator (SAR) or Airline Respirator
Demand mode
Continuous flow mode
Pressure-demand or other positive-pressure mode
Self-Contained Breathing Apparatus (SCBA)
Pressure-demand or other positive-pressure mode (e.g., open/closed circuit)
10,000

50. Respirator Selection – Maximum Use Concentration (MUC)
Program Requirements
Respirator Selection – Maximum Use Concentration (MUC)
Maximum atmospheric concentration of a hazardous substance from which an employee can be expected to be protected when wearing a respirator.
MUC=APF X OEL
OEL: Occupational Exposure Limits, such as PEL, STEL, Ceiling, Peak Limits.

51. Respirator Selection – Maximum Use Concentration (MUC)
Program Requirements
Respirator Selection – Maximum Use Concentration (MUC)
Whenever the exposures approach the MUC, then select the next higher class of respirator for the employees. Do NOT apply MUCs in immediately dangerous to life or health (IDLH) environments

52. Fit Test
Requirement
Each wearer must be fit tested for the respirator prior to use to ensure that the make, model, and size will provide an acceptable face to face piece fit. The fit test method used and the periodic update (e.g. annually) must follow either the local regulatory requirements or the manufacturer’s recommendation

53. Requirement Unacceptable Fit Test
Facial hair that comes between the sealing surface of the face piece and face or that interferes with valve function
Any spectacle with temple bars or straps; and
A head covering, goggles, face shield, welding helmet, or other PPE device which pass between the sealing surface of the RPE and the wearer’s face.

54. Fit Test
Requirement
Personnel that conduct fit testing must be evaluated annually and retrained if necessary This training must be provided by the fit test system manufacturing representative or personnel trained by the representatives

55. Fit Test
Quantitative
A quantitative fit test measures the adequacy of a respirator's fit by numerically measuring the amount of leakage into the respirator

56. Fit Test
Qualitative
A qualitative fit test is a pass/fail test that relies on the employee's response to a test agent For a saccharin or Bitrex test, an administrator challenges a subject wearing a respirator with a test aerosol

57. If the subject can taste the test agent, the respirator fails
Fit Test
Qualitative
Prior to conducting the test, the administrator must determine if the subject can detect the test agent
The subject dons the respirator and a fit test hood. The test aerosol (saccharin or Bitrex) is sprayed inside the hood
If the subject can taste the test agent, the respirator fails

58. Fit Test
Seal Check
Perform prior to the donning of a negative or positive pressure tight- fitting face piece respirator Wearer must complete user seal check to determine if the RPE is properly fitted to their face and in accordance with the manufacturer’s instructions

59. Requirements Who should do the training?
End User Training
Requirements
Who should do the training?
The RPC is not required to do the training
Typically done by the training department
Each site must have a documented training program for respirators that covers the following:

60. Must cover: End User Training
The potential and actual hazards for which respiratory protection may be used The adverse effects of exposure if the respirator is not properly used, including signs and symptoms of exposure Tasks and areas for which respiratory protection use is required

61. End User Training
Must cover:
Why the respirator is necessary and how improper fit, usage, or maintenance can compromise the protective effect of the respirator
What the limitations and capabilities of the respirator are, including the replacement requirements for filters and cartridges

62. End User Training
Must cover:
How to put on (don) and remove (doff), use, and conduct the user seal checks and fit test of the respirator

63. End User Training
Must cover:
How to use the respirator effectively in emergency situations, including situations in which the respirator malfunctions, and the use of emergency escape devices, including limited use SCBAs and mouthpiece devices

64. Must cover: End User Training
How to inspect, maintain, and store respirators
How to recognize medical signs and symptoms that may limit or prevent the effective use of respirators
Site specific work rules, such as facial hair policies
Specialized training for workers who wear air-supplying respirators, including SCBAs and airline respirators

65. Equipment Inspection, Storage and Maintenance
Equipment Maintenance
Equipment Inspection, Storage and Maintenance
Inspection
Looking for damage
End of Service Life Indicator (ESLI)
Storage
Respirators must be kept in good condition and free of contaminants.

66. Equipment Inspection, Storage and Maintenance
Equipment Maintenance
Equipment Inspection, Storage and Maintenance
Maintenance
In order to be maintained in a sanitary condition, each respirator should be washed according to the manufacturer’s instructions
Repairs to respirators may only be performed by qualified personnel using only replacement parts approved by the manufacturer

67. Management of Change
Requirements
The site must have a documented process to identify, and control all new respiratory protection related hazards associated with people, equipment, or process changes Hazard Identification Inventories and Risk Assessments must be updated to reflect any changes

68. Requirements REMEMBER - PPE is the least desirable form of control
Program Review
Requirements
REMEMBER - PPE is the least desirable form of control
PPE will only protect if worn correctly and consistently
SOT’s, training, worker and leadership accountability are all required to ensure compliance

69. Requirements Atmosphere exposure incidents, including near-misses
Program Review
Requirements
Atmosphere exposure incidents, including near-misses
Related corrective and preventative actions to ensure timely completion and evaluation trends

70. Requirements Fit testing records
Program Review
Requirements
Fit testing records
Inspection, maintenance, and storage of respirators
Planned inspection records and employee feedback

71. Requirements Work procedures which specify the use of RPE
Program Review
Requirements
Work procedures which specify the use of RPE
Training effectiveness
Assessment of the program against the long-term objective of eliminating the need to wear RPE

72. Program Review
Requirements
Review the results of this program evaluation during the Leadership Review process

73. Proper Documentation of Respirator Program
Program Documentation
Proper Documentation of Respirator Program
Hazard identification and risk assessment documentation
GM Health Services and medical surveillance records
Worker training records

74. Proper Documentation of Respirator Program
Program Documentation
Proper Documentation of Respirator Program
Planned inspection documentation Program evaluation documentation Provide Appendix D to all users of Voluntary Respirators

75. Inventory of Tasks and Required RPE
Program Documentation
Inventory of Tasks and Required RPE
You need to know:
Which tasks require RPE
What RPE is required for those tasks
Who is required to wear it
This includes wearers of Voluntary Respirators
*RPE: Respiratory Protection Equipment

76. Resources Global IH Sharepoint Site https://globalih.share.gm.com/
Respiratory Protection Webpage

77. GM Respiratory Protection site champion training module on GM LMS
Resources
UAW-GM JAS Website, What’s New area, UAW-GM Safety System Audit Performance Standards, Respiratory Protection APS
GM Respiratory Protection site champion training module on GM LMS
Guidelines for Acceptable Respirator Program
%20Acceptable%20Respirator%20Program.doc

78. Questions?

79. Contact Your Regional Industrial Hygienist and UAW IH Technician for more information!