VALERO – KROTZ SPRINGS
SHG #8
Page 1 of 9
Revised 11/18/02
RESPIRATORY PROTECTION GUIDELINE
1.0
PURPOSE
To protect employee health by meeting the requirements of the OSHA respiratory
protection standard CFR 1910.134.
2.0
SCOPE
This guideline applies to anyone who may be exposed to a hazardous atmosphere while
working in the facility.
3.0
DEFINITIONS

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4.0
Air Line Respirators - respirators which supply breathing air to the wearer via a
hose from a pressurized source such as a cylinder or compressor.
Escape Respirator – respirator equipped with a 5-minute air supply used for
escape only.
IDLH - Immediately Dangerous to Life or Health.
NIOSH - National Institute of Occupational Safety and Health
Program Administrator (Safety Manager) - person capable of identifying
respiratory hazards in the workplace and who maintains a common knowledge of
the respiratory standard OSHA 1910.134.
Respirator - an enclosure that covers the nose and mouth or the entire face
used to either filter contaminants from inhaled air or supply breathing air to the
wearer.
Respirator User – anyone who may be exposed to a hazardous atmosphere
and would be required to use a respirator.
SCBA - Self Contained Breathing Apparatus; a type of supplied air respirator
which is used only by trained individuals.
PRACTICES
4.1
General Respirator Practices

Respirators will only be used in circumstances where engineering or
administrative controls are impractical.
Only NIOSH approved respirators will be used in the facility.
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Respirators will be used and maintained in accordance with manufacturers or
OSHA instructions. Alterations are prohibited. Respirators will be used in
conjunction with other required PPE.
Special procedures, rescue procedures, and protective equipment required will
be communicated to personnel by their supervisor before each job.
All respirator users will be fit tested upon initial employment and annually
thereafter.
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SHG #8
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Revised 11/18/02
RESPONSIBILITIES
Responsible
Group/Individual
Responsibilities
Program Administrator/ 
Safety Manager
Approves the selection and purchase of respirator types and brands
made available on site.

Assures that respirator wearers are fit tested and trained annually.

Maintains training, fit testing and respirator inspection and maintenance
records.

Performs an annual program evaluation and takes action as appropriate
to the results of the evaluation.

Coordinates cleaning of reusable face pieces.

Maintains and updates the refinery Respiratory Protection Guideline.
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Initiates SCBA donning drills.
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Determines if engineering or administrative controls are practical to
avoid use of respirators.
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Enforce the provisions of this SHG within their area of responsibility.
Owning Area Supervisor 

Enforce the provisions of this SHG within their area of responsibility.
Lead Tech
Plant Nurse
Employees
Non-Valero Respirator
User
Bring any suspect task, operation or chemical exposure to the attention
of the program administrator for further evaluation regarding the possible
need for respiratory protection.

Have regular inspections of SCBA’s and escape respirators performed in
their area of responsibility to assure their readiness.

Determine the capability of an individual to wear respiratory protective
equipment.

Responsible for fit testing and medical evaluations recordkeeping

Be familiar with and understand the refinery respiratory protection SHG.

Use respirators in accordance with the training and supervisory
instruction provided.

Clean, store or dispose of respirators properly after each use in
accordance with plant procedures.

Immediately report any malfunctions or respirator problems to their
supervisor or the refinery respirator Program Administrator.

Complete the Breathing Air Cart Checklist (ATTACHMENT 1).

Notify their supervisor or the Program Administrator if they experience
any physical or psychological symptom or condition that might
temporarily or permanently affect their ability to wear a respirator.
Have their own respiratory protection program, which meets or exceeds
the requirements of this guideline.

VALERO – KROTZ SPRINGS
6.0
SHG #8
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Respirator Issuance, Availability and Usage
6.1
Respirator Issuance and Availability

The facility supply of respiratory equipment will be purchased and maintained by
the Safety Department.

Employees will be issued respiratory equipment through the Safety Department
for specific job tasks.

Breathing Air Carts containing two (2) supplied air respirators equipped with
escape bottles are available for use. Employees must inspect respirators before
each use. After use, respirators must be properly cleaned, bagged, and put
back in the designated storage boxes. A Breathing Air Cart Inspection Checklist
must be completed after each use and sent to the Safety Clerk.

SCBAs for Emergency Use Only are available in each control room and at
various locations in the facility.

Complex I and II control rooms are equipped with four air line respirators. This
equipment is for unit emergencies.
6.2
Respirator Usage
6.2.1 Air Purifying Respirators
Respirator Type
3M 8233
Particulate Filter
Where Used
Throughout the
facility
Exposure To
Dust, insulating
materials,
Catalysts, welding
fumes
Benzene
3M 6001/5001
Organic Vapor
( Half-mask)
Throughout the
facility
3M 6003 Organic
Vapor/Acid Gas
Throughout the
facility
Sulfur Dioxide(SO2)
Scott-O-Vista
Model 65 (Full
Face)
Throughout the
facility
Benzene, SO2,
Ammonia, H2Sescape only
Use Limits
Never to be used in an
oxygen deficient atmosphere
To be used in environment
where contaminant level is
known. Cannot exceed 10
ppm Benzene
Concentration not to exceed
5 ppm SO2, 10 ppm
Benzene
Not to exceed 50 ppm
Benzene, 5 ppm SO2
NOTE: Air purifying respirator cartridges can be reused. Manufacturer recommendations
include information about the longevity of cartridges. Cartridges used for protection
from exposure to Benzene vapors must be discarded at the end of each shift per the
requirements in the OSHA Benzene Standard.
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SHG #8
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Specific Job Tasks for Air Purifying Respirator
1.
Catalyst loading/unloading or other dust generating work may require the use of a
particulate filter.
2.
Spray painting may require the use of either the Scott-O-Vista or 3M 6000 series if the
gas or vapors exceed permissible levels (see MSDS).
3.
Welding and grinding on stainless or galvanized metals and welding in confined spaces
may require the use of 3M 8233 respirators. A supplied air line respirator will be
required where oxygen levels could be reduced to less than 19.5% or other toxic
materials may exceed allowable exposure limits.
6.2.2 Supplied Air Respirators
Type Respirator
ELSA Escape
Respirator
Where Used
ATS Unit
Used By
All personnel
Exposure To
IDLH conditions
Scott Ska-Pack
Throughout the
facility
All personnel
IDLH
atmospheres
Scott Supplied
Air Respirators
(air line)
Scott SCBA
2a,2.2
Throughout the
facility
Maintenance,
Operations
Throughout the
facility
All personnel
Unknown
atmospheres,
possible IDLH
IDLH emergency
conditions
Scott SCBA 4.5
Throughout the
facility
Emergency
Response Team
IDLH emergency
conditions
Use Limits
Emergency Use
only - 5 minute
maximum time
limit
Emergency Use
Only -5 minute
maximum time
limit
300 ft maximum
air line to
respirator
2216 lbs
pressure
Maximum 30
minute use limit
4500 lbs
pressure 60
minute maximum
time limit
Specific Job Tasks for Supplied Air Respirators

Examples of jobs that may require the use of a supplied air hoseline with escape bottle
includes:
∙
Work in or on product lines and vessels that contain hydrogen sulfide (H2S) gas.
∙
Tank or vessel entry.
∙
Work in inert or purged vessel.
∙
Any work on chlorine or ammonia systems, which could emit gas to the
atmosphere.
∙
Any area or situation where breathable air is contaminated or may become
contaminated with unknown levels of toxic materials or low oxygen(19.5% or less).
VALERO – KROTZ SPRINGS
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SHG #8
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Emergency entry into equipment, vessels, tanks, or areas where unknown contaminant
levels or I.D.L.H. atmospheres may exist, may be performed with SCBA or supplied air
respirators equipped with escape bottle. These situations will include: rescue incidents,
fire fighting, spill response and cleanup, H2S or other leak situations.
NOTE: Procedures for entry into IDLH atmospheres. Refer to SHG #3, Safe Work Permit
Guidelines, section 5.5 Permitting for Confined Space.
7.0
Medical Evaluations
Employees who use or may use respirators will be medically evaluated to verify that they
are physically able to wear and use the respirators assigned prior to their first use. The
medical evaluation will be administered by the plant nurse before fit testing. The plant
nurse will be familiar with the stresses induced by the respirators under normal and
emergency conditions.
8.0
Respirator Selection
The Safety Department will identify and evaluate the respiratory hazard(s) in the
workplace. This evaluation shall include a reasonable estimate of employee exposures
to respiratory hazard(s) and an identification of the contaminant’s chemical state and
physical form.
9.0
10.0
Fit Testing and Training

Respirator users will be annually fit tested on all face piece styles available.
Records of the results for each individual tested will be maintained by the
Program Administrator.

Respirator users will be trained at least annually on the proper pre-use
inspection, use, care, cleaning, storage, and limitations of the respirators
available within the refinery. Operators and Emergency Response Team
members who have the potential to wear emergency use respirators will be
required to participate in donning drills to keep their familiarity with these
respirators at a high, proficient level.
Maintenance/Inspection/Storage
10.1
Cleaning and 1 Maintenance
Cleaning and Maintenance of reusable respirators is handled through the Safety
Department. A supply of clean face pieces and respirators will be maintained in
the Safety Department. All used respirators and face pieces will be returned to
the Safety Department for cleaning.
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10.2
10.3
SHG #8
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Pre-use Inspection

Respirator components should be inspected by the user prior to each
use. The following procedures should be followed:
(i)
Check the facepiece for cracks, tears and dirt.
(ii)
Examine exhalation valves and valve covers for signs of
distortion, cracking, or tearing. Lift valves and inspect valve seat
for dirt or cracking.
(iii) Make sure the head straps are intact and have good elasticity.
(iv) Examine all plastic parts for signs of cracking or fatigue. Make
sure the filter gaskets are properly seated and in good condition.

A positive and negative fit check should be performed prior to each use.
(See respirator instruction manual for proper procedure.)

A respirator with any damaged components should be brought to the
Safety Department for removal from service. A new respirator will then
be issued if necessary.
Storage

A respirator should be stored in a sealed plastic bag when clean and not
in use.

The cleaned and bagged respirator should be stored away from
contaminated areas when not in use.
Note: Respirators are not to be stored or left uncleaned and
unbagged in any area of the facility.
10.4 Supplied Air Quality Verification

Supplied air/breathing air cylinders must have on record a certificate of
analysis from the vendor. The cylinders will be tested by the Safety
Department staff for quality.

All supplied air breathing cylinders (2500 & 6000 psi) will be tagged
(ATTACHMENT 2) with inspector’s name and date. Thirty minutes
cylinders, one-hour SCBA cylinders and 5-minute escape bottles are
exempt from tagging.
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12.0
SHG #8
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Revised 11/18/02
Recordkeeping

All records such as training, respirator inventories and locations, formal
maintenance, inspections, and program evaluations are kept by the Program
Administrator.

Any records pertaining to fit testing and individual medical evaluations are kept
by the Plant Nurse.

All records are kept for a period of five years.
Program Evaluation
Program evaluations are the responsibility of the Program Administrator and will be
conducted annually. Any program improvements identified as well as final actions or
decisions made regarding these improvements will be documented in a letter to file by
the Program Administrator.
References:
OSHA Directive CPL 2-2,54A
CFR 1910.134
CFR 1926.103
Appendix A / B-1 / B-2 / C / D
NIOSH Guide to Respiratory Protection
VALERO – KROTZ SPRINGS
SHG #8
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Revised 11/18/02
ATTACHMENT 1
BREATHING AIR CART INSPECTION CHECKLIST
DATE/TIME
CART#
LOCATION:
RESPIRATOR USER(S) NAME(S)
JOB PERFORMED
OK
NOT
OK
Bottle pressure
Hose line in good condition properly stored
Mask cleaned, disinfected, bag sealed
Alarm working properly
All fittings tight – no leaks
COMMENTS:
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ATTACHMENT 2