UNC Respiratory Protection
Program for Energy Services
CoGeneration Facility
Mechanical Maintenance Work Units
Presented by
UNC-CH Environment, Health &
Safety
Class Objectives
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•
•
•
•
Introduction to the Respiratory Protection Program
Review of General Work Operations -Respirator Use
Review of Potential Health Hazards Present
Review of Respirator Types Used
Review Respirator Manufacturer Operating & Maintenance
Instructions
• Review Respirator Fit-Testing Procedures
• Complete Post-Test
Introduction
The University of North Carolina at Chapel Hill (UNC-CH)
Respiratory Protection Program describes written policy and
procedures for the use of respirators to protect the health of
employees in accordance with the Occupational Safety and
Health Administration’s (OSHA) Respiratory Protection
Standard, 29 CFR 1910.134 (General Industry Respirator
Standard).
Respirator Use: Maintenance Work Requirements
An evaluation was performed for the use of respirators at the CoGeneration
(CoGen) Facility.
A review of the respiratory protection program was performed with CoGen site
supervisors/superintendents at later dates.
The evaluation consisted of conducting a site visit to tour plant areas and to
interview work unit supervisors and employees in areas where respirators are used.
Our goal was to determine if the type of respiratory protection currently used is
sufficient. Findings were shared with the Workplace Safety Manager and plant
superintendents.
Based on the evaluation findings, respirators are stored and used at the
CoGeneration facility for both general operations/maintenance work
requirements and for emergency response use during emergency response
situations.
This training module covers general operations/maintenance work
requirements for respirator use, not emergency response use. Emergency
Response use will be covered in a separate training module.
Respirator Use: Maintenance Work Requirements
Findings: Only specific employees at the facility use and require
respirators for general operations and maintenance work requirements.
Not all employees at CoGen need to be enrolled in the UNC-CH Respiratory
Protection Program based on survey results.
Primarily Maintenance Mechanics (Boiler Mechanics) and Fuel Handlers
(Coal & Ash Mechanics) have been issued and use respirators and are
enrolled in the UNC-CH Respiratory Protection Program (RPP).
Respirator Use: Maintenance Work Requirements
Respirators are properly stored inside a designated storage locker at the
CoGen Plant. The respirators appeared to be in good material condition
and are properly maintained.
Respirator Use: Maintenance Work Requirements
Maintenance Mechanics (Bolier Mechanics) are issued North full face &
half-face air purifying respirators (APRs) equipped with P100 filters and
combination chemical cartridges for infrequent plant boiler cleaning and
inspection operations. 3M 8511 N95 filtering facepiece respirators are also
worn during part of this process.
The primary inhalation hazard is exposure to coal dust during the use of
the plants Milling Machine and (Fly Ash) particulate matter from the coal
burning process during the cleaning and inspection process of the boiler
plant components. The respirators currently used by the Boiler Mechanics
are acceptable and protective against coal dust and fly ash.
A half-face N95 filtering facepiece respirator is the recommended
respirator for up to 10 times (x) the applicable Occupational Exposure
Limit (OELs) for coal dust. The OELs are the OSHA permissible exposure
limit (PEL) and the ACGIH Threshold Limit Value (TLV).
The following slide indicates a summary of work processes, potential
health hazards, recommended respirators, filters and cartridges.
Respirator Use: Maintenance Work Requirements
Boiler Mechanic Maintenance Respirator Recommendations
Minimum
Respirator
Recommended
Filters/Chemical
Cartridges
Required
Work Task
Potential Hazard
Inspecting & Cleaning
out the interior of the
Plant Mills
Coal dust
Disposable filtering
facepiece (e.g. N95)
Either N, R, P, 95, 99,
or P100 filters
When entering in the
various areas of the
plant boilers to perform
inspections, cleaning,
and maintenance work
Fly Ash
Full face air purifying
respirators
P100 filters
Replacing the baghouse
filters; and opening the
hoppers to inspect the
filters
Fly Ash
Disposable filtering
facepiece (e.g. N95)
Either N, R, P, 95, 99,
or P100 filters
During “heavy” aerosol
paint operations and
when cleaning plant
equipment
Organic vapors
Full face air purifying
respirators
Combination chemical
cartridges;
*(acid gas when
cleaning acid tanks)
*(caustic and acid when
cleaning caustic and acid
tanks)
Respirator Use: Maintenance Work Requirements
Coal dust health hazard information (from OSHA Health Guidelines
Literature):
Good industrial hygiene practices requires that engineering controls be
used where feasible to reduce workplace concentrations of hazardous
materials to the prescribed exposure limit.
However, some situations may require the use of respirators to control exposures in
accordance with OSHA guidelines. Conditions for respirator use (in accordance with
OSHA health guidelines) to control exposures to coal dust include:
Respirators must be worn if the ambient concentration of coal dust
exceeds the prescribed exposure limits.
Respirators may be used:
1) Before engineering controls have been installed
2) During work operations such as maintenance or repair activities that involve
unknown exposures
3) During operations that require entry into tanks or closed vessels
4) During emergencies
Respirator Use: Maintenance Work Requirements
Routes of exposure for coal dust exposure can occur through inhalation,
ingestion, and eye contact.
The signs and symptoms of exposure to coal dust include:
Acute exposure: symptoms of inhalation of excessive amounts of coal dust
include coughing, wheezing, and shortness of breath.
Chronic exposure: Chronic exposure to coal dust may result in symptoms
of chronic bronchitis and emphysema. Coal dust causes coal workers’
Pneumoconiosis (CWP).
Complicated CWP is characterized by lesions consisting of a mass of
rubbery well defined black tissue that is often adherent to the chest wall.
This is associated with decrements in ventilatory capacity, low diffusing
capacity, abnormalities of gas exchange, low arterial oxygen tension,
pulmonary hypertension, and premature death.
Respirator Use: Maintenance Work Requirements
Milling Machine Used to Crush Coal: Mechanics use N95 disposable
respirators when inspecting/cleaning out the interior of the Plant Mills.
Respirator Use: Maintenance Work Requirements
Fly-Ash Health Hazard Information:
Fly ash (one of several coal combustion products) is the finely divided
mineral residue resulting from the combustion of coal in electric generating
Plants.
Fly ash consists of inorganic, incombustible matter present in the coal that
has been fused during combustion into a glassy, amorphous structure.
Fly ash material solidifies while suspended in the exhaust gases and is
collected by electrostatic precipitators or filter bags.
Fly ash particles are generally spherical in shape and range in size from
0.5um (micrometers) to 100 um. Particles mostly consist of silicon
dioxide, aluminum oxide, and iron oxide. Fly ash may also contain trace
concentrations of heavy metals known to be hazardous to health in
sufficient amounts.
Respirator Use: Maintenance Work Requirements
Excessive exposure to Fly ash dust can cause short term acute health
effects:
Eye Contact: Can cause abrasive irritation. Prolonged exposure can lead
to ulceration of the eye (this is why Full face APRs are used!);
Skin Contact: Can cause dermatitis in susceptible individuals (primarily
due to high PH, alkalinity).
Inhalation: Fly ash itself is classified as non-toxic. Health effects are
dependent on duration of exposure and the exposure concentration of the
chemical constituents present in Fly Ash (e.g. crystalline silica content and
heavy metals content which both can cause ill health effects, based on the
concentrations of these contaminants).
Respirator Use: Maintenance Work Requirements
Full face Air Purifying Respirators (APRs) are also used when entering the
various areas of the boiler for protection against Fly-Ash from the coal
burning process.
Respirator Use: Maintenance Work Requirements
Full face Air Purifying Respirators (APRs) equipped with P100 filters are
also used when entering the various areas of the boiler for protection
against Fly-Ash from the coal burning process.
Respirator Use: Maintenance Work Requirements
Full face Air Purifying Respirators (APRs) equipped with P100 filters are
also used when entering the various areas of the boiler for protection
against Fly-Ash.
Cyclone
Respirator Use: Maintenance Work Requirements
N95 filtering facepiece disposable respirators are used when replacing the
baghouse filters or when opening the hoppers to inspect the filters.
(Two Bag houses)
(6-7 hoppers/per baghouse)
Respirator Use: Maintenance Work Requirements
Employees should ensure the respirator is properly donned and a user seal
check is performed prior to entering the contaminated work environment.
Employees who handle or potentially come into contact with coal dust or
Fly Ash should follow proper personal hygiene procedures including
thoroughly washing hands, forearms, and face with soap and water before
eating, using tobacco products, using toilet facilities, or taking medicine.
If coal dust or fly ash contacts the skin, employees should wash the affected
areas with soap and water.
Respirator Use: Maintenance Work Requirements
Maintenance Mechanics also use various aerosol chemical lubricants,
cleaners, and aerosol can paints on occasion during maintenance and
repair work. Respirators are sometimes worn during “heavy” aerosol can
spray painting operations after refurbishing plant equipment and when
cleaning plant equipment (e.g. process tanks, caustic and acid tanks).
The actual frequency and duration of these operations is variable. The
primary potential hazard is exposure to organic vapors from the chemical
ingredients and skin and eye exposure to caustic and acid chemicals. The
respirator and chemical cartridges used (with combination chemical
cartridges) is protective against organic vapors found in aerosol can spray
paints, lubricants, and cleaners, and acid gasses.
Respirator Use: Maintenance Work Requirements
When possible apply aerosol cans of paints, lubricants, cleaners, etc, in
well-ventilated areas and remain upwind when possible.
Do not apply chemical products in poorly ventilated areas without the use
of supplemental ventilation or respiratory protective equipment.
Ensure all other required personal protective equipment is worn (e.g.
chemical protective gloves such as disposable nitrile gloves, eye protection
such as safety glasses or chemical goggles).
Contact the EHS Industrial Hygiene Section at 3-2735/3-7313 during
“heavy” spray operations and caustic and acid tank cleaning operations so
these processes can be further evaluated.
Respirator Use: Maintenance Work Requirements
Findings: Coal and Ash Mechanics also use respirators when unloading
coal and limestone from railcars inside the coal unloading facility.
Respirator Use: Maintenance Work Requirements
3M 8511 N95 filtering facepiece respirators are used by Coal and Ash
Mechanics when unloading coal from railcars.
Additional full face and half face tight-fitting elastomeric respirators are
maintained for use by some of the mechanics. Respirators are also used
when sweeping and cleaning the railcar unloading area weekly as needed.
However, contractors perform “heavy” cleaning operations.
Respirators are available and properly stored in a sanitary location at the
coal and ash control room.
Respirator Use: Maintenance Work Requirements
Engineering Controls Used to Minimize Dust Exposure: The
railcar unloading area is equipped with a built in water sprinkler system to
suppress dust when generated from the unloading process when needed.
There is a dust suppression activation panel both in the railcar unloading
area and in the Coal and Ash Control Room (as pictured on the first page of
this survey). Built in dust collection devices (additional engineering
controls) are used in different areas of the coal transfer system.
Respirator Use: Maintenance Work Requirements
Coal and Ash Mechanics have not recently unloaded limestone, because it
is currently being trucked in and delivered via an enclosed process.
Respirators are not generally worn during the coal unloading or transfer
process, but they are available when needed.
The limestone unloading process (when using railcar) consists of
positioning the loaded railcar in the facility, using a mechanical vibrator to
shake material from the railcar. The material then settles into a hopper
underneath and the material is then piped to the boiler plant.
Employees reportedly do not perform any physical removal or disturbance
of the limestone, they remain in the control room during the unloading
process and only have to be positioned in the railcar unloading process for
short periods of time as needed during this process.
However, due to the dust levels, employees use respirators (3M 8511 N95
filtering facepiece respirators) when entering the railcar unloading
area even for short periods of time.
Respirator Use: Maintenance Work Requirements
Information from the National Institute of Occupational Safety and Health
(NIOSH) about Limestone
Respirator Use: Maintenance Work Requirements
Information from NIOSH about Limestone (Pure Calcium Carbonate):
Used to neutralize acidic coal air emissions.
Physical description: Odorless, white to tan powder.
Incompatible & reactive with acids, ammonium salts, fluorine,
magnesium
Routes of exposure: Includes inhalation, ingestion, and/or eye contact
Signs and symptoms of acute exposure include: Irritation to the eyes,
skin, respiratory system, and cough.
Target Organs: Eyes, skin, respiratory system (However, it is claimed that
pure calcium carbonate does not cause adverse health effects including
pneumoconiosis).
Respirator Use: Maintenance Work Requirements
Information from NIOSH about Calcium Oxide (CaO):
Sometimes CaO is a component of Limestone that is a mixture (0 - 43%)
Physical description: White or gray, odorless lumps or granular powder.
Incompatible with water (reacts with water to form calcium hydroxide).
Routes of exposure: Includes inhalation, ingestion, and/or eye contact
It is more hazardous compared to pure limestone
Signs and symptoms of exposure include: Irritation to the eyes, skin,
upper respiratory tract, ulcer, perforation of the nasal septum,
pneumonitis, and dermatitis.
Target Organs: Eyes, skin, respiratory system
Respirator Use: Maintenance Work Requirements
Findings: The National Institute of Occupational Safety and Health
(NIOSH) recommends the use of any particulate respirator (N,R,P series)
equipped for up to 10 times the OEL for calcium oxide.
The type of respirator used by Coal and Ash Mechanics (3M 8511 N95
filtering facepiece) is adequate if properly worn and properly fitted.
Respirator Use: Maintenance Work Requirements
Continue to use a half-face N95 filtering facepiece respirator with safety
glasses or chemical goggles when entering the railcar unloading area
during the unloading of limestone from railcars. A half face or full face
air-purifying respirator with N, R, or P100 filters may also be worn.
Ensure the respirator is properly donned and a user seal check is
performed prior to entering the area where limestone dust is being
generated.
Employees should prevent skin and eye contact and wash affected skin
areas if exposed. If eye exposure occurs, the eyes should be irrigated
immediately by using an emergency eyewash or quick drench.
Recommend that this process (rail car unloading process of limestone or
aragonite) be monitored by our IH Department when the process resumes
in the near future.
Respirator Use: Maintenance Work Requirements
Coal and Ash Mechanic Maintenance Requirements
Work Task
Potential Hazard
Minimum
Respirator
Recommended
Unloading limestone
from railcars*
Limestone*
(calcium carbonate &
potentially calcium
oxide)
Disposable filtering
facepiece (e.g. N95)
*Refer to the product
MSDS for actual
constituents present &
percentage
*A half or full face air
purifying respirator may
also be used instead of a
disposable respirator
*When entering the
railcar unloading area
during unloading or
physical removal of
product
Performing
maintenance
operations on the
coal transfer system
or anytime visible
high levels of coal
dust are generated
(Need to change to
include new
Filters/Chemical
Cartridges
Required
Either N, R, P, 95, 99,
or P100 filters
Disposable filtering
facepiece (e.g. N95)
Coal dust
*A half or full face
air purifying
respirator may also
be used instead of a
disposable
respirator
Either N, R, P, 95,
99, or P100 filters
Review of Respirator Types Used
Review of North 7600 Full Face Air
Purifying Respirator Operating and
Maintenance Instruction Manual
&
3M 8511/8211 Particulate N95 Instruction
Manual
Review of Respirator Types Used
North 7600 Series Full Face Air Purifying Respirator Operating and
Maintenance Instructions
Read and Understand Operating and Maintenance Instructions (handout
provided)
General Warnings: This respirator is not to be used in Immediately Dangerous to
Life or Health (IDLH) atmospheres.
An IDLH atmosphere is any atmosphere which has a concentration of any toxic,
corrosive, or asphyxiant substance that poses an immediate threat to life, which
would cause irreversible debilitating effects on health, or which would interfere
with the ability to escape from a dangerous atmosphere.
IDLH is also an atmospheres where the concentration of the contaminant exceeds
the respirator’s Maximum Use Concentration. This is where the concentration of
the contaminant exceeds: 100 times the contaminant’s permissible exposure limit
(the maximum permissible 8-hour time weighted average (TWA) concentration)
established by applicable OSHA or other government regulations, or by NIOSH or
ACGIH publications.
Review of Respirator Types Used
North 7600 Series Full Face Air Purifying Respirator Operating and
Maintenance Instructions
Read and Understand Respirator Operating and Maintenance Instructions
(handout provided)
General Warnings: Do not use any air purifying respirator when conditions
prevent a good facepiece-to-face seal.
Examples of such conditions are:
The growth of beards, bangs, or sideburns which will pass between the
facepiece sealing area and the face;
The use of head or face coverings which contain materials which will pass
between the facepiece sealing area and the face (e.g. head bandannas).
Review of Respirator Types Used
North 7600 Series Full Face Air Purifying Respirator Operating and
Maintenance Instructions
Read and Understand Respirator Operating and Maintenance
Instructions (handout provided)
Immediately leave the contaminated area if:
1)
2)
3)
4)
5)
Breathing becomes difficult
Dizziness or other distress occurs
You smell, taste or sense irritation from the contaminants
The air purifying element is equipped with an End-of-Service-Life
Indicator which has changed color to indicate expiration, or
The respirator becomes damaged.
Review of Respirator Types Used
North 7600 Series Full Face Air Purifying Respirator Operating and
Maintenance Instructions
Inspections: You are required to perform an inspection of the respirator prior to
use. Inspect all components of the respirator prior to use (e.g. straps, facepiece).
Periodic Seal Checks: Each time that the respirator is put on, before entering an
area containing hazardous atmospheres, and periodically while wearing the
respirator in the contaminated area, the respirator wearer should check the
effectiveness of the seal of the facepiece to the wearer’s face by carrying out a
negative and positive pressure seal check (turn to page 8 of instruction manual).
Positive Pressure Check
Negative Pressure Check
Review of Respirator Types Used
North 7600 Series Full Face Air Purifying Respirator Operating and
Maintenance Instructions
Review Page 6, pre-use instructions (facepiece, filters, assembling the
respirator, corrective lenses)
Review Page 7-8, Putting on the respirator
Adjust the head straps
Spreading the head strap
Placing the facepiece on your head
Tightening the lower head straps
Tightening the upper head straps
Tightening the forehead head strap
Review of Respirator Types Used
North 7600 Series Full Face Air Purifying Respirator Operating and
Maintenance Instructions
Review Page 10,
Chemical cartridge change out schedule
Particulate filters
Taking off the respirator
Filter and cartridge replacement
Inspection
Storage
Review Page 11
Cleaning and Sanitizing
Review of Respirator Types Used
North 7600 Series Full Face Air Purifying Respirator Operating and
Maintenance Instructions
Now, Practice the donning of the respirator and perform both a positive
and negative user seal check.
You should feel comfortable with donning your respirator without
assistance.
Your respirator fit-test score will depend on your ability to properly don
the respirator and to obtain an appropriate fit with the respirator.
Review of Respirator Types Used
3M 8511 Particulate N95 Respirator Operating and Maintenance
Instructions
Read and Understand Operating and Maintenance Instructions (handout provided)
The filtering facepiece respirator that you use has a NIOSH approval Rating of
N95: This means the respirator has been tested by NIOSH to provide at least 95%
filtration efficiency against solid (particulate) and liquid aerosols that do not
contain oil.
Examples of ok uses include: particles generated from sweeping, sawing,
bagging, or processing minerals, coal, iron, ore, wood, pollen, liquid, or non-oil
based particles from sprays that do not also emit oil aerosols or vapors.
This respirator may not be used for protection against gasses and vapors, oil
aerosols, toxic metals (e.g. cadmium, lead), or ok particles in concentrations that
exceed 10 times their OSHA standard. Not to be used in IDLH atmospheres (toxic
and oxygen deficient atmospheres).
Review of Respirator Types Used
3M 8511 Particulate N95 Respirator Operating and Maintenance
Instructions
Fitting Instructions: The following procedure must be followed each time
the respirator is worn (procedure is from the 3M 8511 instruction manual
handout):
1)
Cup the respirator in your hand, with the nospiece at your fingertips,
allowing the headbands to hang freely below your hand.
2)
Position the respirator under your chin with the nosepiece up. Pull
the top strap over your head resting it high at the top back of your
head. Pull the bottom strap over hour head and position it around
the neck below the ears.
Review of Respirator Types Used
3M 8511 Particulate N95 Respirator Operating and Maintenance
Instructions
Fitting Instructions: The following procedure must be followed each time
the respirator is worn (procedure is from the 3M 8511 instruction manual
handout):
3)
Place your fingertips from both hands at the top of the metal
nosepiece. Using two hands, mold the nose area to the shape of your
nose by pushing inward while moving your fingertips down both
sides of the nosepiece.
4)
Perform a User Seal Check prior to each wearing. To check the
respirator-to-face seal, place both hands completely over the
respirator and inhale sharply. Be careful not to disturb the position
of the respirator. A negative pressure should be felt inside the
respirator. If air leaks around the nose, readjust the nosepiece as
described in step 3.
Respirator Fit-Testing Procedures
Employees at UNC-CH are required to receive a quantitative fit test
with the respirator that they will be using. The fit-testing will occur
prior to initial use of the respirator, or whenever a different respirator
facepiece (size, style, model, or make) is used, and at least annually
thereafter.
An additional fit-test is conducted annually thereafter and whenever
the employee, supervisor, the Environment, Health, and Safety,
or the UEOHC makes visual observations of changes in the employee’s
physical condition that could affect respirator fit.
Such conditions include, but are not limited to, facial scarring, dental
changes, cosmetic surgery, or any obvious change in body weight. The
employee may select a different respirator if he/she does not think the
respirator fit is acceptable, even after passing the test.
Respirator Fit-Testing Procedures
Quantitative fit testing is an assessment of the adequacy of
respirator fit by numerically measuring the amount of leakage
into the respirator. Testing is accomplished by modifying the
face piece to allow sampling inside the face piece in the
breathing zone of the user, midway between the nose and
mouth. This requirement is accomplished by using a sampling
adapter designed to temporarily provide a means of sampling
air from inside the face piece.
Respirator Fit-Testing Procedures
A quantitative fit-test determines a fit-factor for the employee based on the type
of the respirator used. A fit-factor is a quantitative estimate of the fit of a
particular respirator to a specific individual, and estimates the ratio:
Fit Factor = Concentration of particles in the ambient air
Concentration of particles inside the respirator
when worn
To pass the fit-test, you need to obtain a fit-factor of at least 1,000.
After the test, the fit-test report will indicate your overall fit-factor.
This sums up this training module, now you will need to take the Post Test!!
Any questions
regarding UNC-CH
Respiratory Protection
Program, please call:
Workplace Safety @ 9625507
1120 Estes Drive Ext.
Campus Box 1650
Chapel Hill, NC, 27599
References
1)
U.S. Department of Labor, Occupational Safety and Health Administration
Guidelines for Coal Dust: http://www.osha.gov
2)
National Institute for Occupational Safety and Health, NIOSH Pocket
Guide to Chemical Hazards: http://www.cdc.gov/niosh/npg
3)
Material Safety Data Sheet for Limestone, Martin Marietta Materials; 2710
Wycliff Road, Raleigh, NC 27607
4)
Materials Safety Data Sheet for Coal Fly Ash, Pro-Ash; Baltimore Gas and
Electric STI Processed Ash, LLC.