Module-5
Personal Protective Equipments
NOTICE
September 2010 5.03-0011-2010
Bhopal
PERSONAL PROTECTIVE
EQUIPMENTS REQUIRED
BEYOND THIS POINT
Contents
1. Introduction
-2
2. Head Protection
-3
3. Eye and Face Protection
-4
4. Hearing Protection
-5
5. Skin Protection
-6
6. Body Protection
-7
6.1. Leather Apron -6.6. Suspension Belts
- 7-8
7. Hand and Arm Protection
-9
7.1. Leather Gloves - 7.7. Hand Sleeves
- 9-10
8. Leg and Foot Protection
- 11
8.1. Safety Boots and Shoes - 8.10. Slip-in-type Safety Boots
- 11-12
9. Respiratory Protection
- 13
9.1. Nominal Protection Factor - 9.3 Noteworthy point for Respiratory Protective Equipment
- 13-15
10. Limitations of personal protective equipment
- 16
11. Glossary
- 29
12. References
- 30
Personal Protective Equipment (PPE) means any device or appliance designed to be worn or
held by an individual for protection against one or more health and safety hazards.
PPE also includes:

a unit constituted by several devices or appliances which have been integrally
combined by the manufacturer for the protection of an individual against one or more
potentially simultaneous risks;

a protective device or appliance combined, separably or inseparably, with
personal non-protective equipment worn or held by an individual for the
execution of a specific activity;

interchangeable components which are essential to its satisfactory functioning and
used exclusively for such equipment.
1. Introduction
Personal Protection implies the provisions and use of various types of Personal Protective
Equipment (PPE), such as safety boots, ear protectors, aprons, gloves. As such it may be
considered as either last resort, when all other methods of protection have failed or purely as
an interim form of protection until the hazard can be eliminated at source or controlled by some
form of 'safe place' strategy, such as machinery guarding or the installation and use of local
exhaust ventilation system. Personal Protective Equipment includes a wide range of
equipment worn and used by people at work to protect them from both general and specific
hazards. As such, it includes:

Head Protection: Safety Helmets, Bump caps, Caps and Hair nets.

Eye Protection: Goggles, Safety Spectacles, hand held or freestanding screens.

Face Protection: Face shields, which can be hand held, fixed to helmet or strapped
to head.

Respiratory Protection: General-Purpose Dust Respirators, Positive Pressure
Powered Respirators, Helmet Contained Positive Pressure Respirators, Gas
Respirators,

Emergency Escape Respirators, Airline Breathing Apparatus, Self-Contained
Breathing Apparatus

Hearing Protection: Ear Plugs, Ear Defenders, Muffs and Pads, Ear Valves, Acoustic
Wool.

Skin Protection: Barrier Creams

Body Protection: One Piece and Two Piece Overalls, Donkey Jackets, Aprons,
Warehouse Coats, Body Warmer, Oilskin Over Clothing, Chemical Clothing.

Hand and Arm Protection: General Purpose Fibre Gloves, PVC Fabric Gauntlets,
Gloves, Sleeves, Chain Mail Hand and Arm Protectors.

Leg and Foot Protection: Safety Boots, Shoes, Wellingtons, Gaiters and Anklets.
As an employer, you must assess your workplace to determine if hazards are present that
require the use of personal protective equipment. If such hazards are present, you must
select protective equipment and required workers to use it, communicate your protective
equipment selection decisions to your workers, and select personal protective equipment
that properly fits your workers. You must also train workers who are required to wear
personal protective equipment on how to do the following:

Use protective equipment properly,

Be aware of when personal protective equipment is necessary, Know what
kind of protective equipment is necessary,

Understand the limitations of personal protective equipment in protecting
workers from injury,

Put on, adjust, wear, and take off personal protective equipment, and maintain
protective equipment properly.
2. Head Protection
There are four widely used types of head protection:

Crash Helmets; protect against impact with moving objects Industrial Safety
Helmets; protect against falling objects or impact with fixed objects

Bump Caps; protect against scalping or entanglement

Caps and Hair nets; protect scalping or entanglement
Much will depend upon type and form of the risk an individual is exposed to in terms of
head protection required. For head protection to be suitable, it must fit the wearer
properly, be of an appropriate size and have an easily adjustable headband, nape and
chin strap. An ideal head protection does not hinder the work being done, and has
compatibility with other PPE, such as ear and eye protectors, being worn at the same
time. The sizes in which industrial helmets are available in the market:
Type of Head
Band Size
Small500
-540 mm
Medium540
-590 mm
Large590
-640 mm
Caps have adjustable lace arrangement.
This is the text for the pictures:
Orange six point ratchet suspension safety helmet with nylon webbing, Ear Muffs, Visor
Bracket and Nylon Visor.
Safety signage should be displayed in those areas where the hard hat is required.
3. Eye and Face Protection
Eye protection serves to guard against the hazards of impacts, splashes from chemicals
or molten metal, liquid droplets (chemical mists and sprays), dusts, gases, welding arcs,
non-ionising radiation and the light from lasers. There are four principal forms of eye
protection:

Safety Spectacles, which may incorporate optional shields, with lenses
manufactured in tough optical plastic, such as polycarbonate, and available
with standard or prescription lenses.

Eye shields designed with frameless one-piece moulded lens. Safety goggles
manufactured with toughened glass lenses or wide vision plastic lenses, with
flexible plastic frame and elastic head band.

Face shields, which are fitted with adjustable head harness, and provide
protection to the face as well as the eyes.
These lenses of eye protectors must be kept clean as dirty lenses restrict vision which
may cause fatigue and may be contributing feature in accident.
(a) Side shield type, net type, fitted with blue or clear lenses (b) Panorama, Leather mask,
Gas cutting goggles (c) Asbestos hood, Aluminised hood (d) Plastic face shield, welding
head shield, welding hand shield
Mandatory sign for face shield
Safety signage should be displayed in those areas where the eye protection is required
4. Hearing Protection
The hearing protection must be in use where exposure to noise level of 90dbA or above
exists. Before use it must be ensured that the form of hearing protection chosen would
produce the necessary attenuation (Sound Pressure Reduction) at operator's ear.
4.1 Ear Plugs
These are manufactured in plastic, rubber, glass down or combination of these materials
and are fitted in to the auditory canal. If fitted properly they may attenuate the noise
reaching ear by 25-30dBA. They may be of the permanent or disposable type. Training for
method of insertion in to ear canal is must. These provide ample protection in the work
environment with noise level of 155-120dBA. Recent development is polymer foam which
gives effective fitment without any pain or strain in the ear.
4.2 Ear defenders, Muffs and Pads
These cover whole ear and can reduce exposure by up to 50dBA at certain frequencies.
They can be uncomfortable in hot conditions and may be difficult to wear with safety
spectacles or goggles. These provide ample protection against sound level of 130135dBA.
4.3 Ear valves
These are inserted in to auditory canal, in theory, allow ordinary conversation to take place
while preventing harmful noise reaching ear.
Safety signage should be displayed in those areas where hearing protection is required
5. Skin Protection
There are many chemical substances which cause skin lesions or dermatitis and are more
commonly used in the work places. These include strong acids and alkalis, chromates
and dichromate, formaldehyde, organic solvents, resins, certain adhesives, suds,
degreasing compounds and lubricants. Paraffin and trichloroethylene removes the natural
fats from the skin and render it vulnerable to damage from other substances.
A range of barrier creams is available to meet varying work conditions. The selection shall
be based upon the chemical to be handled. They provide skin protection in wet conditions,
and for workers handling acids, alkalis and other potentially hazardous substances. The
barrier creams must be applied before commencement of work.
6. Body Protection
A wide range of protective clothing for the body is available, including:





Coverall, Aprons; protects against chemicals & hazardous substances
Outfits to protect against cold, heat and bad weather
Specific clothing to protect against machinery, such as chain saws
High Visibility clothing
Life jackets and buoyancy aids
6.5 Safety Belt and Harness





In the selection of body protection, the following factors are relevant;
The degree of personal contamination from the task or process e.g. dust, oil, general soiling, chemicals and other
hazardous substances etc.;
The ease, cost or washing or dry cleaning;
The degree of exposure to temperature and humidity variations;
Possible discomfort etc.
6.1 Leather Apron
These provide protection against the sharp objects, hot chips, oil spillages and abrasion by rough surface or objects. These
are generally supplied with tapes and buckles for proper tying.
6.2 Asbestos Apron
It is used to protect body from heat. These may have lint lining or leather lining, depending upon the nature of work for which
they are to be used.
6.3 PVC Apron
It is used to protect from the chemical spillages, acid splashes, paints and coolants.
6.4 Lead Apron
It provides protection from the ionising radiations e.g. X-rays, gamma rays, etc.
Person working at the height of 10ft (02m) or above must use safety belt. It provides protection
against fall from height.
6.6 Suspension Belts
For application where it is not possible to work from a fixed surface and the worker must be
totally supported by suspension harness e.g. shipboard painting, stack maintenance etc.
Mandatory sign for body belt
7. Hand and Arm Protection
Damage to hands and arms can arise through the use of machinery and hand tools and in manual handling operations;
resulting in cuts and abrasions, through skin irritation, contact with hazardous substances and as a result of exposure to
adverse weather conditions. A wide variety of hand and arm protection is available including gloves and gauntlets made of
leather, chain mail, PVC fabric and man-made fibres. The gloves should not be used while working with moving machinery
such as drills, saws, grinders etc. These machines may catch the gloves, pull it with hand of worker in to the hazardous area.
Safety signage should be displayed for instruction.
7.1 Leather Gloves
These protect the hands from cuts, bruises and abrasions. Fit for handling sharp edged materials.
7.2 Asbestos Gloves
These provide protection to the hands from heat thereby avoid burn injuries. These gloves are provided with double-padded
lining inside. These may withstand with temperature as high as 1000 C.
7.3 Acid and Alkali Proof Gloves
These have the black cover. These protect the workers only against the harmful effects of Acid & Alkali materials.
7.4 Electrical Resistant Gloves
The colour of these gloves is Red. These protect against the electric shock. These must be purchased along with their
inspection/test certificates.
7.5 Canvas Gloves
These provide protection against oil, grease and other dirt.
7.6 Lead Gloves
These provide protection against ionising radiations like X-rays and gamma rays.
7.7 Hand Sleeves
These are designed to give protection to the full length of hand (from shoulder to arm) of the wearer. Mainly used by the
welders for protection against slag and metal spatters while doing position welding.
(a) Canvas Gloves, Acid and Alkali proof rubber gloves, Leather Gloves, Asbestos Gloves
(b) Aluminised gloves, Crust Leather Gloves (Front & Back View) (c) Safety Belt-Body harness and Life line.
Safety signage for gloves
8. Leg and Foot Protection
Safety footwear used in many industries and occupations e.g. construction, mechanical and manual handling activities, for
work in cold and wet conditions, foundry work and forestry.
8.1 Safety Boots and Shoes
These are the most common type of safety footwear and commonly incorporate a steel toe cap. They can also have other
safety features, such as slip resistant soles, steel insoles and insulation against extreme temperatures etc.
8.2 Asbestos Safety Boots
Used for heat radiation area. The upper part is made of asbestos; the remaining part of this boot is made of Asbestos. The
remaining parts, material and construction are same as Safety boots.
8.3 Clog
Wooden clogs, frequently fitted with steel toe caps, are traditionally used in number of industries.
8.4 Foundry Boots
These incorporate steel toe caps, are heat resistant and designed to protect the foot against molten metal splashes and
spillages. They are designed without external features such as laces which trap molten and commonly have elasticised sides
for quick removal.
8.5 Wellington Boots
These protect against water and wet conditions and are useful in occupations where footwear needs to be washed and
disinfected for hygienic reasons, such as with food industry workers. They are manufactured in rubber, polyurethane and PVC,
and may feature corrosion-resistant steel toe caps, rot-proof insoles, and steel mid soles, ankle bone padding and cotton
linings.
8.6 Gaiters
These are commonly used in foundries to provide protection to the ankles from splashes of
molten metal. They are manufactured in leather and compositions of leather, Hessian and
other fibrous materials.
8.7 Anti-static Footwear
These prevent the build up of static electricity on the wearer. They reduce the danger of igniting a
flammable atmosphere and give some protection against electric shock.
8.8 Conductive Footwear
This type of footwear also prevents the build up of static electricity, and is particularly suitable for
handling sensitive components or substances e.g. Explosive Detonators. It gives no protection
against electric shock.
8.9 Leg Guard
These are recommended for use by welders and also to avoid the entering of sparks inside the
safety boot.
8.10 Slip-in-type Safety Boots
This is a combination of safety boots and leg guards; gives full protection to welders.
Aluminised Safety Boot, Asbestos Safety Boot, Gum Boot, Leg Guard, Leather Safety Boot.
9. Respiratory Protection
The use of Respiratory Protective Equipment (RPE) is essential wherever workers are exposed to dangerous concentrations
of toxic or fibrogenic dusts, fumes or where they may be working in un-ventilated or poorly ventilated areas. The correct
selection and use of RPE is absolutely vital. For instance, the use of face masks is definitely not recommended against
anything other than low concentrations of nuisance particulate matter or atomised liquids.
9.1 Nominal Protection Factor
BS 4275 refers to the selection of RPE and lists Nominal Protection Factor (NPF) for different forms of equipment. The NPF
measures the theoretical capability of RPE and is calculated thus:
NPF=Concentration of contaminant in atmosphere / Concentration of contaminant in face piece
9.2 Forms of Respiratory Protection Equipment
9.2.1 Face Masks
These are simple devices for holding filtering media against the nose and mouth to remove coarse nuisance dust particles or
non-toxic paint sprays. They must not be used as a means of protection against hazardous or toxic substances.
9.2.2 General Purpose Dust Respirator
They take the form of an ori-nasal face mask which has a particulate filter to trap the finely divided solids or liquid particles.
9.2.3 Positive Pressure Powered Dust Respirator
These comprise an ori-nasal face mask fitted to a power-driven pack carried on individual and connected by a flexible hose.
They are more effective than the simple form of dust respirator as they utilise a much more efficient filtering medium and
operate with positive pressure in the face-piece.
a) Typical Half Mask Respirator, Typical Quarter Mask Respirator
b) Detailed View of Heavy Cartridge Respirator and Dust Respirator
c) Front and Back Mounted Canister Gas Mask
9.2.4 Helmet-contained Positive Pressure Respirator
This form of device provides head, face, eyes and lung protection together with high degree of comfort. It incorporates a
helmet and visor with high efficiency axial fan mounted on the rear of the helmet, which draws the dust laden air through a
coarse filter. The partially filtered air is then passed through a fine filter bag. The filtered air provides a cool pleasant air stream
over the entire facial area, and is finally exhausted at bottom visor at a flow rate sufficient to prevent dust entering the mouth
or nose.
The low-voltage electric power is supplied by a light weight rechargeable battery pack, connected to the helmet by means of
flexible cable. This portable battery pack may be clipped to a belt or carried in overall pocket.
9.2.5 Gas Respirator
The respirator takes the two forms; cartridge and canister. The cartridge respirator is similar to dust respirator. It uses a
chemical cartridge filter and is effective against relatively low concentration of designated gases or vapours below a specified
low level of concentration. Canister Respirators on the other hand are normally of full piece type, the exhaust valves,
incorporating goggles and visor. They are connected to chemical filter for protecting against specified low concentrations of
designated toxic gases or vapours. The manufacturer's instruction on avoidance of cartridge/canister saturation, maximum
period of use in relation to gas concentration in air, shelf-life etc. must, in all cases be carefully followed. They are effective
against toxic gases and vapours in limited concentrations only. A particulate filter can be incorporated to remove dust
particles.
9.2.6 Emergency Escape Respirator
These are especially designed respirators using a chemical filter which will enable people to escape from dangerous
atmospheres in an emergency. They are intended for very short term use and should never be used twice or for normal
protection.
9.2.7 Air-line Breathing Apparatus
This apparatus consists of a full mask or half mask connected by flexible hose either to a source of uncontaminated air (short
distance) or to a compressed airline via a filter and demand valve. This apparatus is usually safe for use in any contaminated
atmosphere but is limited to length of airline, which also places some restriction on movement. When using a fresh air hose a
pump is necessary for lengths over 10 meters. The quality of fresh air has to be carefully evaluated!
9.2.8 Self-Contained Breathing Apparatus (SCBA)
Limitation of the hose mask/ airline type breathing equipment is the trailing hose which may result in entanglement and the
wearer must return by retracing his route in the contaminated atmosphere. The SCBA is self sufficient breathing equipment
that permits freedom of movement as the wearer carries the supply of breathable air. The following three types are available:
1.
2.
3.
Demand type compressed oxygen or Compressed Air Breathing Apparatus
Compressed Oxygen recirculation breathing apparatus
Oxygen generating type breathing apparatus
This device can be of the open or closed circuit type. The open circuit type supplies air by lung-governed demand valves or
pressure reducers connected to a full face-piece via a hose supply. The hose is connected to its own compressed air or
oxygen supply which is carried by wearer in his harness. The closed circuit type incorporates a purifier to absorb exhaled
carbon dioxide. The purified air is fed back to respirator after mixing with pure oxygen. Both of these devices are used in
dangerous atmospheres or where there is a deficiency of oxygen, or for rescue purposes from confined spaces.
9.3 Noteworthy point for Respiratory Protective Equipment
 Use air purifying apparatus only if the contaminant level in the air is less than 2% by volume. Use chemical cartridge only
if contaminant level is less than 0.1% or the concentration specified by manufacturer.
 Use canister only on knowing the colour codification, nature of contaminant and its shelf life. Use only for 02hrs or the
time limit specified by manufacturer. Maintain records for usage.
 Check for any physical damage before use e.g. punctures in hose, filter, etc.
 Use hose mask if pure atmosphere is within the reach of 20ft and the area is free from any hurdle or heat that has the
potential to damage hose/air line.
 RPE shall be used with a standby person or helper present in the work area.
 Develop a system and implement effectively to ensure timely cleaning and disinfection of RPE. Follow the manufacturer
recommendation for cleaning. The following procedures may also be followed:
 Remove all filters, cartridges, canisters, etc.
 Scrub and clean the face piece components with soap and warm water to remove grease, a hand brush may be used
if required.
 Immerse the face piece in warm water for 05minutes and rinse it to clean.
 Immerse the face piece in solution of Formalin (01 part of 40% of formaldehyde and 09 parts of water) or in solution of
Sodium hypo chloride (01 parts of it in 09 parts of water) for 05 minutes.
 Again rinse the face piece with cold water and air dry them in a clean place.
10. Limitations 0f personal protective equipment
The use of PPE shall serve the purpose only when it is used with knowledge of its
limitations. Especially the limitations of PPE must be known by the person who is going to use it. In any hazardous
environment the use of PPE should be considered only as the last line of defence.
PPE does not help in any way in removing or reducing the prevailing hazard conditions in environment; but it only provides
limited and time bound protection. It is because of this reason PPE is not considered as a panacea for the hazards; it is the
last line of defence. The best way of ensuring full protection can only be achieved by eliminating the hazards by proper
engineering and administrative control measures.


Use of PPEs needs care from risk angle so that persons wearing the PPEs should not be hurt during the use of
PPEs.
One simple thumb rule will not be applicable for all types of the hazards and PPEs.

Proper hazards assessment and guidelines need to be followed - annexure 1 and 2 provides light in brief in
general.

Annexure 3 provides in depth, as an example, what type of PPEs must be used during handling of acid.
Appendix 1
Companies must do the hazards assessment and must recommend the PPEs
Certification of hazard assessment
The following steps must be followed on priority Assessment date(s):
Department: .......................................................................................................................
Building: .............................................................................................................................
Task or assignment description: .........................................................................................
Hazards identified:
Eye and Face: .....................................................
Respiratory: ..........
Head:
Foot:
Electrical: ........................................................
Hand: ....................
Whole Body: ......................................................
Other: ...................
PPE requirements:
Eye and Face: ........................................................................
Respiratory: ..................
Head: ..................................................................................
Foot: .............................
Electrical: ............................................................................
Hand:............................
Whole Body: ..........................................................................
Other: ...........................
Other control measures: ......................................................................................................
CERTIFICATION: I certify this hazard assessment was conducted in accordance with the provisions.
Name of certifying supervisor:
Date:
Appendix 2
Guidelines for hazard assessment and Personal Protective
Equipment selection
I. Controlling Hazards
PPE devices alone should not be relied on to provide protection against hazards, but should be
used in conjunction with guards, engineering controls, and sound work practices.
II. Assessment and Selection
When assessing a task and selecting means of hazard control it is the responsibility of the
supervisor to exercise common sense and appropriate expertise to accomplish assessment and
selection requirements. He should also refer to the hazards identification report. See also
Module-9 (Job Safety Analysis).
III. Assessment Guidelines
A. Survey
Conduct a walk-through survey of the areas in question. The purpose of the survey
is to identify sources of hazards to workers and co-workers. Consideration
should be given to the basic hazard categories:
1.
Impact
2.
Penetration
3.
Compression (Roll-Over)
4.
Chemical
5.
Heat
6.
Harmful dust
7.
Light (Optical) Radiation
B. Sources
During the walk-through survey, the safety officer should observe:
1.
Sources of motion; i.e. machinery or process where any movement of tools,
machine elements or particles could exist, or movement of personnel that
could result in collision with stationary objects;
2.
Sources of high temperatures that could result in burns, eye injury or ignition
of protective equipment, etc.;
3.
Types of chemical exposures;
4.
Sources of harmful dust;
5.
Sources of light radiation, i.e. welding, brazing, cutting, furnaces, heat
treating, high-intensity lights, etc.;
6.
Sources of falling objects or potential for falling from height;
7.
Sources of sharp objects which might pierce the feet or cut the hands;
8.
Sources of rolling or pinching objects which could crush the feet;
9.
Layout of workplace and location of co-workers; and
10.
Any electrical hazards; in addition; injury/accident data should be reviewed to
help identify problem areas.
C. Organise data
Following the walk-through survey, it is necessary to organise the data and
information for use in the assessment of hazards. The objective is to prepare for
an analysis of the hazards in the environment to enable proper selection of
protective equipment.
D. Analyse data
Having gathered and organised data on a workplace, an estimate of the potential
for injuries should be made. Each of the basic hazards should be reviewed and a
determination made as to type, level of risk, and seriousness of potential injury
from each of the hazards found in the area. The possibility of exposure to several
hazards simultaneously should be considered.
IV. Selection Guidelines
After completion of the general procedure for selection of protective equipment is to:
A.
B.
C.
D.
E.
Become familiar with the potential hazards and the type of protective equipment that is available, and what it can
do, etc. i.e. splash protection, impact protection, etc.;
Compare the hazards associated with the environment; i.e. impact velocities, masses projectile shape, radiation
intensities, with the capabilities of the available protective equipment;
Select the protective equipment which ensures a level of protection greater than the minimum required to protect
the employee from the hazards;
Fit the user with the protective device and give instructions on care and use of the PPE;
Ensure that end users be made aware of all warning labels for and limitations of their PPE.
V. Fitting the Device
Careful consideration must be given to comfort and fit. PPE that fits poorly may not afford the necessary protection. Continued
wearing of the device is more likely if it fits the wearer comfortably. Protective devices are generally available in a variety of
sizes.
Care should be taken to ensure that the right size is selected.
VI. Devices with Adjustable Features
Adjustments should be made on an individual basis for a comfortable fit that will maintain the protective device in the proper
position. Particular care should be taken in fitting devices for eye protection against dust and chemical splash to ensure that the
devices are sealed to the face. In addition, proper fitting of helmets is important to ensure that it will not fall off during work
operations. In some cases, a chin strap may be necessary to keep the helmet on an employee's head. (Chin straps should
break at a reasonably low force, however, so as to prevent a strangulation hazard.) Where manufacturer's instructions are
available, they should be followed carefully.
VII. Reassessment of hazards
It is the responsibility of the supervisor to reassess the workplace hazard situation as necessary, by identifying and evaluating
new equipment and processes, reviewing accident records, and re-evaluating the suitability of previously selected PPE.
VIII. Selection guidelines for eye and face protection
Some occupations for which eye protection should be routinely considered are: carpenters, electricians, machinists, mechanics
and repairers, millwrights, plumbers and pipe fitters, sheet metal workers and tinsmiths, assemblers, sanders, grinding machine
operators, lathe and milling machine operators, sawyers, welders, labourers, chemical process operators and handlers, and
timber cutting and logging workers. The appended chart provides general guidance for the proper selection of eye and face
protection to protect against hazards associated with the listed hazard “source” operations.
IX. Selection guidelines for head protection
All head protection is designed to provide protection from impact and penetration hazards caused by falling objects. Head
protection is also available that provides protection from electric shock and burn. When selecting head protection, knowledge of
potential electrical hazards is important.
Class A helmets, in addition to impact and penetration resistance; provide electrical protection from low-voltage conductors
(they are proof-tested to 2,200 volts). Class B helmets, in addition to impact and penetration resistance; provide electrical
protection from high-voltage conductors (they are proof-tested to 20,000 volts). Class C helmets provide impact and
penetration resistance. They are usually made of aluminium which conducts electricity and should not be used around
electrical hazards.
Where falling object hazards are present, helmets must be worn. Some examples include: working around or under conveyor
belts which are carrying parts or materials; working below machinery or processes which might cause material or object to fall;
and working on exposed energized conductors. Some examples of occupations for which head protection should be routinely
considered are: carpenters, electricians, linemen, mechanics and repairers, plumbers and pipe fitters, assemblers, packers,
wrappers, sawyers, welders, labourers, freight handlers, timber cutting and logging workers, stock handlers, and warehouse
labourers.
X. Selection Guidelines for Foot Protection
Safety shoes and boots which meet the Standard provide both impact and compression protection. Where necessary, safety
shoes can be obtained which provide puncture protection. In some work situations, metatarsal protection should be provided,
and in other special situations, electrical conductive or insulating safety shoes would be appropriate. Safety shoes or boots with
impact protection would be required for carrying or handling materials such as packages, objects, parts or heavy tools, which
could be dropped; and for other activities where objects might fall onto the feet. Safety shoes or boots with compression
protection would be required for work activities involving skid trucks (manual material handling carts) around bulk rolls (such as
paper rolls) and around heavy pipes, all of which could potentially roll over an employee's feet. Safety shoes or boots with
puncture protection would be required where sharp objects such as nails, wire, tacks, screws, large staples, scrap metal, etc.,
could be stepped on by employees causing a foot injury.
Some occupations (not a complete list) for which foot protection should be routinely considered are: shipping and receiving
clerks, stock clerks, carpenters, electricians, machinists, mechanics and repairers, plumbers and pipe fitters, structural metal
workers, assemblers, drywall installers and lathers, packers, wrappers, craters, punch and stamping press operators, sawyers,
welders, labourers, freight handlers, gardeners and groundskeepers, timber cutting and logging workers, stock handlers and
warehouse labourers.
XI. Selection Guidelines for Hand Protection
Gloves are often relied upon to prevent cuts, abrasions, burns, and skin contact with chemicals that are capable of causing
local or systemic effects following dermal exposure. It is important to select the most appropriate glove for a particular location
and to determine how long it can be worn, and whether it can be reused. It is also important to know the performance
characteristics of gloves relative to the specific hazard anticipated (e.g. chemical hazards, cut hazards like flame hazards,
etc.) Their performance characteristics should be assessed by using standard test procedures. Before purchasing gloves, the
employer should request documentation from the manufacturer that the gloves meet the appropriate test standard(s) for
hazard(s) anticipated.
A. Other factors to be considered for glove selection in general include:
1.
As long as the performance characteristics are acceptable in certain circumstances, it may be more cost-effective
to regularly change cheaper gloves than to reuse more expensive types, and;
2.
The work activities of the employee should be studied to determine the degree of dexterity required, the duration,
frequency, and degree of exposure of the hazard, and the physical stress that will be required.
B. With respect to selection of gloves for protection against chemical hazards:
1.
The toxic properties of the chemical(s) must be determined; in particular, the ability of the chemical to cause local
effects on the skin and/or pass through the skin and cause systemic effects;
2.
Generally, any “chemical resistant” glove can be used for dry powders;
3.
For mixtures and formulated products (unless specified test data are available), a glove should be selected on the
basis of the chemical component with the shortest breakthrough time, since it is possible for solvents to carry
active ingredients through polymeric materials; and,
4.
Employees must be trained to remove the gloves in such a manner as to prevent skin contamination.
XII. Cleaning and Maintenance
It is important that all PPE be kept clean and properly maintained. Cleaning is particularly important for eye and face protection
where dirty or fogged lenses could impair vision.
PPE should be inspected, cleaned, and maintained at regular intervals so that the PPE provides the requisite protection. It is
also important to ensure that contaminated PPE which cannot be decontaminated is disposed of in a manner that protects
employees from exposure to hazards.
Appendix 3
Frequently asked questions on PPEs
Q. What kind of PPE is used when loading/unloading acid?
A. The recommended PPE for unloading/loading sulphuric acid is a hard hat, chemical goggles with a
face shield, acid splash suit, rubber gloves and boots. The acid splash suit is typically a coated
PVC material. An acid hood can be worn in place of the chemical goggles and face shield.
Q. Do you need respiratory protection for sulphuric acid?
A. Respiratory protection is not required when handling non-fuming (<100%) sulphuric acid under
normal conditions. Fuming sulphuric acid >100% (also known as oleum) may require an acid mist
cartridge respirator or a supplied breathing source, based on the type of job and exposure
monitoring results.
Q. Can you wear a face shield instead of chemical goggles?
A. A face shield can be worn over the chemical goggles, but should never be worn in lieu of the
goggles. With a face shield, acid can spray in from the side or from underneath the face shield - the
eyes do not have "positive" coverage from a face shield.
Q. What do you wear in your plants?
A. The type of Personal Protective Equipment (PPE) worn on our sites depends on the type of job and
potential hazard associated with that job. For a plant walk-through, the minimum recommended
PPE is a hard hat and chemical goggles. For low-hazard jobs, such as operating valves and
pumps, the minimum recommended PPE is a hard hat, chemical goggles and acid resistant
gauntlet-length gloves. For higher level potential hazard jobs, such as loading or unloading acid, a
hard hat, chemical goggles, face shield, acid-resistant gauntlet-length gloves, acid resistant splash
suit (not a rain coat) and acid-resistant boots, preferably steel-toed, are recommended. For 1st
breaks into lines or other equipment that contained acid, the minimum PPE recommended is an
acid-resistant hood, acid-resistant gauntlet-length gloves, acid- resistant splash suit and acid
resistant-boots.
Q. From whom can I buy the acid gear?
A. The acid gear can be purchased from a number of different suppliers. Make sure the suit material is
truly acid-resistant for the % sulphuric acid you are handling on your plant site (i.e., make sure the
suit is good for 93% acid, not just 20% acid, if you handle 93% on your site). Also make sure the
suit is properly designed to minimize tears/rips at the arm-pits and crotch. Make sure the suit is
properly sized. DuPont Protective Apparel markets several fabrics and styles of suits acceptable for
sulphuric acid service.
Q. How far does a fume cloud of sulphuric acid go?
A. Non-fuming sulphuric acid (<100%) has a very low vapour pressure and does not fume, so it will not
have a fume cloud. If a spill occurs, sometimes people will notice an odour. This odour is usually
the result of the sulphuric acid reacting with something (typically organic), or if the acid reacts with
water and causes a splattering "mist."
Q. What are the main dangers associated with sulphuric acid?
A. The main hazard associated with sulphuric acid is its corrosivity to skin and eyes. It can cause rapid
damage to skin and eye tissue on contact, and may result in burns and/or permanent eye damage.
Another potential with sulphuric acid is that if it is diluted it becomes much more corrosive to most
metals. As the metals corrode, hydrogen gas is evolved. If the hydrogen gas collects (such as in a
room or in a tank) it may reach the explosive range.
Q. Do I need to evacuate for a sulphuric acid spill?
A. The main hazard associated with an acid spill is contact with the liquid, which may result in burns to
the skin and eyes. Evacuate an area large enough to prevent any liquid exposure to the acid. If the
acid spill reacts with any other chemical/object on the ground and a resulting odor/mist is
suspected, evacuate downwind.
Q. What do you use to neutralize/clean up a spill?
A. In general any alkali will neutralize an acid spill. Soda ash, caustic soda, lime, limestone, and baking
soda can be used. A "rule-of-thumb" is to dilute the acid to about 15% before trying to neutralize, if
possible, to minimize the heat generated by the neutralization reaction. Once the pH has been
adjusted to between 2-12, the spill waste can usually be treated as "non-hazardous waste". Verify
this with your local and state regulatory agencies.
Q. What is your plant's Emergency Response Plan for an acid incident?
A. The plant Emergency Response Plan is site-specific, based on the size of the plant, the number of
trained responders typically at the plant at certain times, the availability of trained local community
responders, etc. In general, for non-fuming sulphuric acid, the main consideration would be to
contain the liquid, to keep it out of sewers, waterways and from the groundwater. The main safety
hazard associated with non- fuming sulphuric acid is burns from skin/eye contact. The main
environmental hazard is that it would quickly lower the pH of any water it reaches, causing potential
damage to plants and wildlife. See also Module-13 (On-site Emergency Plan)
Q. What kind of Emergency Response training do your plant people receive?
A. All plant personnel receive the eight-hour OSHA HAZCOM 1910.119 "Right-to-Know" training. Every
three years, plant operation personnel receive training that meets the 40-hr HazWoper training
requirements. Plant personnel also participate in at least one drill per year involving sulphuric acid.
Q. What is the first aid treatment for acid exposure?
A. The first aid treatment for sulphuric acid is fairly simply - get as much water on the affected area, as
fast as possible. Wash/rinse the affected skin area for at least 15 minutes. Follow-up the water
wash by applying a clean terrycloth soaked in ice-water. Continue to apply the ice-cold compresses
until told to stop by a physician. The ice-cold compresses will "pull" the heat away from the burn
area and minimize further damage to the skin tissue. See (also for the following questions) Module4 (First aid in emergency)
Q. Do burn gels work for acid exposures?
A. No. Do not apply any burn gel to a sulphuric acid burn unless specifically told to do so by a physician.
Q. What kind (if any) training do you do with local hospitals/paramedics on acid burn treatment?
A. The plants provide annual training/refresher training to the local hospitals/ paramedics on the
treatment of sulphuric acid exposures.
Q. Are drills recommended for potential acid spill/exposure incidents?
A. Emergency response drills are highly recommended for potential sulphuric acid spills/ exposures. We
conduct quarterly drills with our four rotating shift personnel, so each shift participates in at least
one drill per year.
Exercise-1
Please do the exercise for selecting PPEs while doing maintenance work of a confined space vessel used for
the storage of motor spirit and diesel
Exercise-2
Please do the exercise for selecting PPEs while doing maintenance work of a vessel used for the storage liquid
ammonia
Exercise-3
Do the risk assessment of SCBA, Footwear, Hand gloves, while using them in emergency management of a
area having dense smoke and fire
11. Glossary
Accident:
Any unplanned event that results in injury or ill-health to people, or
damages equipments, property or materials but where there was a risk of
harm.
Active failure:
A human error or violation the effects of which become evident almost
immediately.
Barrier:
Any measure taken to protect people or property from hazards, including
physical guards but also administrative measures such as rules and
procedures - sometimes referred to as safeguards, defences or risk control
systems.
Hazard:
Anything with the potential for human injury or adverse health, damage to
assets or environmental impact. See risk and risk assessment.
Human error:
System failures attributable to people but not including violations.
Human failure:
A term used to collectively refer to both errors and violations.
Human-machine system:
A system in which technology and human beings have specific functions
but work together towards common goals.
Immediate cause (of an incident): The most obvious reason why the incident occurred e.g. The guard is
missing, the employee slips etc. There may be several immediate causes
identified in one adverse event.
Incident:
An unplanned or uncontrolled event or sequence of events that has the
potential to cause injury, ill-health or damage - also referred to as a near
miss.
Lapse:
When a person forgets to do something due to a failure of attention/
concentration or memory.
Major accident hazard:
Hazards with the potential for major accident consequences, e.g. ship
collisions, dropped objects, helicopter crashes as well as process safety
hazards. Major accidents are potentially catastrophic and can result in
multiple injuries and fatalities, as well as substantial economic, property,
and environmental damage.
Occupational safety hazard:
Personal or occupational safety hazards give rise to incidents such as
slips, falls, and vehicle accidents that primarily affect one individual worker
for each occurrence(noting, of course, that they could affect many people).
They contrast with process safety hazards and major accident hazards in
that the latter have the potential to affect a very large number of people
including those off-site.
12. References
1. Factories Act 1948.
2. Personal Protective Equipment, U.S. Department of Labor, Occupational Safety and Health
Administration, OSHA 3151-12R, 2003.
3. Personal Protective Equipment at Work: Guidance on Regulations - ISBN 0-11-886334-7.
4. A short guide to the Personal Protective Equipment at Work Regulations 1992.
5. Indian Factories Act, 1948 and references therein.