CONTENTS
1. SCOPE AND PURPOSE ……………………………………………………….2. REFERENCES 3. DEFINITIONS 4. RESPIRATOR PROGRAM REQUIREMENTS ………………………….5. PROGRAM ADMINISTRATION 6. WRITTEN STANDARD OPERATING PROCEDURES 7. SELECTION, LIMITATION, AND USE OF RESPIRATORS ………..
8. TRAINING 9. RESPIRATOR FITTING TESTS 10. MAINTENANCE, INSPECTION, AND STORAGE …………………….11. WRITTEN COMPLIANCE PLAN 12. EMPLOYEE OPTION 13. RESPIRATOR CARTRIDGES ………………………………………………..
13.1 Cartridge/canister/filter selection and use-warning properties13.2 Storage of cartridges 13.3 Chemical warning properties …………………………………………..13.4 Replacement
Appendix A-Respirator Compliance Plan
Appendix B ……………………………………………………………………………………B.1 Qualitative fit testing B.1.1 Description B.1.2 Precautions …………………………………………………………………B.1.3 Specific procedures B.2 Quantitative fit testing B.2.1 Description ………………………………………………………………….B.2.2 Specific procedures
1. Scope and Purpose
Supplement to ANSI Z88.2-1992 Clause 1.1 “Scope”:
This guide contains information that formerly was in S&OH Guideline 9.13 (Respiratory Protection
Program), Engineering Standards S8H (Fit Testing of Respiratory Protective Equipment), and S9H
(Air-Purifying Respirators Guidelines for Canister/Cartridge use). ANSI Z88.2-1992 is to be followed in its
entirety except where noted below.
The paragraph numbering of the ANSI standard, Sections 1–10, is the
same.
2. References
Supplement to ANSI Z88.2-1992 Clause 2 “Normative References”:
References in addition to those in the ANSI standard are listed here.
1. OSHA Safety and Health Standards, 29 CFR 1910.134.
2. Engineering Standard S1H, “Air Distribution System for Air Masks and Chemical Air Suits.”
3. Engineering Standard S23G, “Interconnection of Process and Service Piping.”
4. NIOSH Publications 76-189, “A Guide to Industrial Respiratory Protection.”
5. Haskell Laboratory Monograph, “Respirator Cartridge—Guidelines and Evaluation.”
6. DHHS (NIOSH) Publication 90-117, “Pocket Guide to Chemical Hazards,” lists IDLH values.
7. DHHS (NIOSH) Publication 91-105 (or latest): NIOSH certified equipment list (latest list).
8. 29 CFR 1910.1001 (Asbestos), Appendix C (Fit Test Methods).
3. Definitions
See ANSI Z88.2-1992.
4. Respirator Program Requirements
Supplement to ANSI Z88.2-1992 Clause 4.2 “Permissible Practice”:
Respirators shall be worn at all times where the atmosphere may be harmful to employees due to unusual
conditions, and where work is necessary in areas where workers may be exposed above safe limits. See
Applicable government limits (e.g., OSHA PELs in the U.S., MAKs in Germany).
Supplement to ANSI Z88.2-1992 Clause 4.5.3 “Physiological and Psychological Limitations for Respirator
Wearers”: Users of respiratory protective equipment shall have annual medical approval in accordance
with Medical Guidelines, Section VI.3. This should be documented in each person’s medical record.
5. Program Administration
Supplement to ANSI Z88.2-1992 Clause 5.2 “Qualifications”:
The administrator shall have attended the SABIC sponsored respirator course or equivalent, should be
completely familiar with the provisions of local laws and regulations dealing with respiratory protection
(U.S. sites use OSHA Regulation 1910.134), and should be a member of the site occupational health
committee (or equivalent).
6. Written Standard Operating Procedures
See ANSI Z88.2-1992.
7. Selection, Limitation, and Use of Respirators
Supplement to ANSI Z88.2-1992 Clause 7.2.1 “Approved Respirators”: In the U.S., equipment approved by
the National Institute for Occupational Safety and Health/Mine Safety Health Administration NIOSH/MSHA)
shall be used when available. This is listed in the NIOSH certified equipment list (reference 7).
Some other countries, e.g., Belgium, have regulations specifying use of certain approved respirators; site
personnel should be knowledgeable concerning local requirements. In countries that have no regulation
requiring use of approved respirators, NIOSH/MSHA, EC, or other nationally certified respirators should be
used, if available.
Supplement to ANSI Z88.2-1992 Clause 7.2.2.2 “Section Steps”: Special respiratory protection may be
required for cancer suspect agents by government regulation. U.S. sites shall refer to OSHA regulations,
Section 1910.1000 series for specific requirements.
Supplement to ANSI Z88.2-1992 Clause 7.2.2.2m “Selection Steps”: If an air-line respirator is to be used,
the hoses should be selected to resist chemicals to which they may be exposed. Also, only hose approved
for that respirator may be used. Air-line units are certified/approved as a complete unit. No substitutions are
allowed since this will void the respirator approval.
Supplement to ANSI Z88.2-1992 Clause 7.3.2 “Respirators for use under IDLH conditions at normal
atmospheric pressure”: Self-contained breathing apparatus (SCBA) rated for at least 30-minute operating
time should be used for entry into potentially IDLH atmospheres.
Self-contained breathing apparatus with less than a 30-minute air supply shall be used only for emergency
egress and not for rescue work or reentry.
Operating time for self-contained apparatus is based upon moderate work rates. Operating time is reduced
by increased respiration required by heavy exertion.
Only positive-pressure self-contained breathing apparatus, or combination air-line respirator and
self-contained breathing apparatus, shall be used in oxygen-deficient atmospheres or where the
contaminant is, or might be, immediately dangerous to life and health. The air in the self-contained unit
worn in combination with an air-line respirator shall be used only for egress in event the hose-line supply of
air is interrupted. The volume of this exit supply may vary for different applications, but shall be ample to
allow the worker sufficient air to escape from the contaminated area. In any case, this supply shall not be
less than 5 minutes.
Emergency Entry Respirators
—
Use self-contained breathing apparatus with at least a 30-minute air supply
or a combination supplied-air respirator with self-contained breathing air apparatus. Unit shall be of the
Pressure demand type. The entry masks should be located outside of the potentially affected area in a on
contaminated area and properly identified and protected.
Five-minute and 15-minute SCBA are for emergency escape only. They are not to be used for reentry or for
work. Their use is acceptable only when employees are effectively trained to don the equipment rapidly
and properly and know its limitations. People who may need to use these respirators for escape should
have an opportunity to don the equipment at a frequency necessary to maintain proficiency (a minimum of
semiannually).
Fire Fighting—Use self-contained breathing apparatus with at least a 30-minute air supply. Unit shall be the
pressure-demand type.
When the device is a combination self-contained breathing apparatus and air-line respirator (supplied-air
respirator), either a manual or automatic valve(s) shall be provided to change to the self-contained air
supply if the air-line supply fails, and to prevent the wearer breathing contaminated air
from the outside atmosphere. If a manual valve is provided, it shall be easily operable and located in a
position that is convenient to the wearer. If an automatic valve is provided, a warning also shall be provided
to alert the wearer that he/she is breathing from the self-contained air supply,
(1) when his/her normal air-line supply fails, or (2) when the self-contained air supply falls below 95% of its
full container pressure. A quick disconnect and check valve shall be provided between the apparatus and the air-line supply hose to permit ready escape from the area, and to pre-vent loss of breathing air from the
device or inhaling the surrounding atmosphere, respectively.
Supplement to ANSI Z88.2-1992 Clause 7.5.1 “Facial Hair”:
No person who has any facial hair within the sealing area shall be fit tested.
To fairly enforce such a policy, sites need to:
– Determine the jobs that require respirators.
– Determine which types of respirators are acceptable for use in that job. For example, in some cases,
respirators that do not rely on a seal to the face can be used (such as air-line hoods).
For those jobs that require respirators that have a face seal, a policy that requires employees to be
clean-shaven in the face sealing area needs to be enforced. Examples of how to make this determination
are provided below, “Guidance for Facial Hair and Respirators”.
” Guidance for Facial Hair and Respirators
To effectively and fairly enforce a no beard policy, a determination of respirator jobs, potential exposures,
and required respirators needs to be made. Respirator jobs include both normal assignments and
potential emergency response activities. For example, a process operator may regularly take process
samples, but in emergency situations may be expected to enter into IDLH atmospheres. These may
involve rescue of downed personnel, closing of process valves during emergencies, or a requirement to
man a control room during process upsets. Any of these activities could involve IDLH or expected IDLH
situations. Potential exposures include both normal operations where measurements are made and
potential exposures that may occur. For example, in activities such as first breaks, a respirator is required
in case the line has not been effectively cleared. Such activity may require an air-supplied, tight-fitting
respirator depending on the chemicals present.
The required respirators should include all types that can be used; for example, where a half mask is used,
an air-line hood or powered air-purifying respirator equipped with a hood could also be used.
Consideration needs to be given to the work activity that may limit the type of respirator that can be used;
for example, an air-line respirator cannot be used for jobs that require a lot of climbing on ladders.
Once this information is assembled, if any respirator job requires a tight-fitting respirator and cannot be
done with another type of respirator, then that job requires each person to be clean shaven. Generally,
operators in areas with materials that are acutely toxic, emergency response teams and much of the
mechanical area personnel will be required to be clean shaven.
Respirators that do not rely on a face seal include hoods, helmets and suits. Powered air-purifying
respirators that include a loose-fitting face-piece such as the Racal Air-stream or 3M W316 Airhat include
a face seal—people using these must be clean shaven. Both manufacturers have other models of PAPRs
that do not rely on a face seal.
Supplement to ANSI Z88.2-1992 Clause 7.5.3.1:
Full-face masks have been developed with systems for mounting corrective lenses inside the facepiece.
Contact the manufacturers for assistance. A half-mask facepiece should not interfere with the wearer’s
use of spectacles or goggles. Proper selection of equipment normally will eliminate any problem of proper
fit when using a combination of half-mask face-piece and spectacles or goggles.
8. Training
Supplement to ANSI Z88.2-1992 Clause 8.1.3 “Respirator Wearer”: The required fit check that is
mentioned in this section is discussed in more detail in ANSI Z88.2-1992 Annex A.6. These fit checks are
also known as the negative pressure or positive pressure functional fit test. With both fit checks be careful
that hand pressure does not distort the position of the facepiece.
Supplement to ANSI Z88.2-1992 Clause 8.1.4 “Emergency and Rescue Teams”:
People who may use an SCBA under emergency situations should have an opportunity to don the
equipment at a frequency necessary to maintain proficiency (a minimum of semiannually).
Supplement to ANSI Z88.2-1992 Clause 8.3 “Records”:
Records should be kept for three years.
9. Respirator Fitting Tests
Change to ANSI Z88.2-1992 Clause 9:
A discussion of qualitative and quantitative fit testing and fit test protocols are in Appendix B of this guide o
use the protocols in 29 CFR 1910.1001 (reference 8).
U.S. sites: Note that use of quantitative fit testing is required for negative-pressure respirators in OSHA
regulations for: Asbestos (29 CFR 1910.1001), Asbestos—construction (29 CFR 1926.62) and
Lead—construction (29 CFR 1926.58) where other than half-mask respirators are required. OSHA also
requires quantitative fit testing for Acrylonitrile (29 CFR 1910.1045) and Arsenic (29 CFR 1910.1018)
when there are more than a minimum number of employees involved.
Supplement to ANSI Z88.2-1992 Clause 9.1.1 “Acceptance Criteria”:
Each employee who wears a negative-pressure, tight-fitting respirator during normal work shall be
fit-tested using an acceptable qualitative method such as the isoamyl acetate or saccharin method or using
a quantitative method.
Change to ANSI Z88.2-1992 Clause 9.1.2 “Positive-Pressure Respirators”:
Replace first sentence of ANSI with the following: Each employee who wears a positive-pressure,
tight-fitting respirator in an emergency shall be fit-tested, using an acceptable qualitative method such asthe isoamyl acetate or saccharin method or using a quantitative method, in a negative-pressure mode.
Supplement to ANSI Z88.2-1992 Clause 9.1.4 “Respirator”: U.S. sites should note that some OSHA
standards require semi- annual fit testing, e.g., 1910.1001(g)(3) “Asbestos,” 1910.1018 “Inorganic
Arsenic,” 1910.1025 “Lead,” 1910.1045 “Acrylonitrile,” 1910.1001, 1926.58 “Asbestos”—construction, and
1926.62 “Lead”—construction.
Supplement to ANSI Z88.2-1992 Clause 9.4 “Respirator Fit Test Records”:
Records should be kept for three years.
10. Maintenance, Inspection, and Storage
Supplement to ANSI Z88.2-1992 Clause 10.3 “Parts Replacement and Repair”:
Note that each stored emergency use respirator such as SCBA shall be inspected monthly per
manufacturer’s instructions and repaired as necessary.Major repairs to SCBA regulators shall be
performed only by the vendor or his certified representative (perhaps a site employee). The date of the
check, inspector and condition of equipment should be recorded.On equipment where it is possible, the
regulator diaphragm should be checked for integrity at least quarterly (refer to the manufacturer’s
instructions).
Supplement to ANSI Z88.2-1992 Clause 10.4 “Storage”:
Respirators should not be left in the work zone where they might become contaminated with workplace
chemicals or be used by other than the as-signed user. The preferred storage is in a clean plastic box or
bag in a cabinet/locker specially designated for respirator storage.
Supplement to ANSI Z88.2-1992 Clause 10.5.1 “Air Quality”:
The ANSI/CGA G-7.1.1989 requirements are as follows:
A closed-circuit (rebreathing) system recirculates exhaled air, makes up oxygen and removes undesirable
gases such as carbon dioxide. Pure oxygen must be used with these systems. Systems approved by the
National Institute for Occupational Safety and Health (NIOSH) that use a high-pressure cylinder for
oxygen may be used.
Supplement to ANSI Z88.2-1992 Clause 10.5.4.1:
Where bottled breathing air is provided by an off-site vendor, the supplier should be visited to determine
the method used for producing air (reconstitution or compression), possibilities for air contamination or
incorrect cylinder labeling and the adequacy of the vendor’s quality control pro-gram.
After the bottled air is received at the site, it should be analyzed as described in ANSI Z88.2-1992, Table 3.
In addition, a complete analysis should be conducted periodically to assure compliance with the table,
above.
Annual contacts should be made to assure equipment and procedures have not changed.
Supplement to ANSI Z88.2-1992 Clause 10.5.4.2:
If an air compressor is used, it should be non-lubricated. If a lubricated compressor is used, it must have a
carbon monoxide or high-temperature (or both) alarm.
Supplement to ANSI Z88.2-1992 Clause 10.5.4.3:
One method of checking for condensed hydrocarbons is to pass a sample of the air to be tested through
an adequate filter (0.8 mm MCEF) and measure the weight gain in the filter.
Supplement to ANSI Z88.2-1992 Clause 10.5.4.5:
Piping, fittings, connectors, etc., for piped breathing air systems from plant air compressors or a cascade
bottle system shall be according to SABIC Engineering Standards G04-S02 properly identified. Manifold
station connectors should be dedicated for breathing air purposes and incompatible with other connectors
used on the plant. It is also preferred that breathing air be only from dedicated systems. In new
construction, there shall be no interconnection of breathing air systems to process systems or other air
systems. Where the same compressor or air receiver provides both breathing air and process air
(instrument or plant), safeguards must be provided to prevent contamination of the breathing air if system
failure, suckback, etc., occurs. There shall be no tee-ins or cross-connections with site process lines; e.g.,
nitrogen for instrument backup.
11. Written Compliance Plan
11.1 In the U.S., where respirators are used regularly for exposures above an OSHA permissible exposure
limit, a compliance plan should be written to document engineering controls considered, plans to
implement the controls, or further study required. The plan should be reviewed annually. An example of a
suitable format for a compliance plan is shown in Appendix A
of this guide.
12. Employee Option
12.1 If respirators are provided at the desire of workers when exposure levels are below permissible limits,
the respirator program administrator may choose to allow optional use. In an optional use situation, fit
testing is not required and facial hair in the seal area need not be prohibited if
a. no foreseeable condition could cause exposure limits to be exceeded,
b. optional use situations are clearly separated from areas where respirators are required, and
c. respirator wearers are instructed annually that fit testing is necessary and facial hair is prohibited
when respirators are worn for protection against airborne chemical concentrations exceeding
exposure limits. All other requirements of the respirator program must be followed, including medical
approval, and the rationale of the exemption must be documented.
13. Respirator Cartridges
13.1 Cartridge/canister/filter selection and use-warning properties
13.1.1 Air-purifying canisters, cartridges and filters used with respirators shall be selected based on the
hazard involved (dusts, mists, vapors, fumes, gases) and must be used only with the brand and model of
respirator for which they are intended, e.g., MSA canister with MSA mask. No one cartridge or canister
respirator is acceptable for use with all gases and vapors. Each vendor provides a list of limitations that
should be consulted. These are not identical for all vendors. Care must be used in choosing elements and
establishing useful lifetimes.
13.1.2 All canisters and cartridges are identified with labels by the manufacturer. In the U.S. a secondary
means is color coding as specified by OSHA in 29 CFR 1910.134.
13.1.3 Canister masks labeled “all service,” “all purpose” or “universal” should not be used if a canister is
available for the specific gas or vapor of interest, unless specifically demonstrated to be adequate.
13.1.4 Generally, if a canister/cartridge type has adequate breakthrough times (see Section 13.4) for the
use contemplated, it should provide adequate protection subject to the limitations noted in Sections 13.3
and 13.4, and the protection factor afforded by the respirator facepiece.
13.1.5 For some chemicals in the U.S., i.e., vinyl chloride, formaldehyde and benzene, OSHA specifies
what type of canister/cartridge must be used.
13.1.6 Cartridges and canisters should be replaced at the end of the task, or according to a documented
schedule based on airborne chemical concentrations and breakthrough times. Some test data are
available from Haskell Laboratory (Reference 5). If plant experience is available for material with adequate
warning properties, the replacement schedule may be based on that experience.
13.1.7 An effective system should be instituted to remind employees when cartridges need to be changed,
e.g., by dating the cartridges when they are put in service. If the odor, taste, or irritation of the contaminant
in question is noticed before the scheduled replacement, the cartridge(s)/ canister should be changed.
Some government regulations for certain chemicals require change of cartridges at specified times.
13.1.8 Air-purifying respirators shall not be used for protection against gases or vapors with inadequate
warning properties except as indicated below. According to NIOSH, a substance has adequate warning
proper-ties when its odor, taste or irritation effects are detectable and persistent at concentrations
a. at or below the permissible exposure limit, or
b. not in excess of three times the limit, when there is no ceiling limit and it is considered that
undetected exposure in this concentration range could not cause serious or irreversible health
effects.
13.2 Storage of cartridges
13.2.1 Cartridges and canisters should be stored in a cool, dry location and protected from humidity and
contamination. In most cases, a plant stores environment is acceptable.
13.2.2 Cartridges and canisters shall be left sealed in the original pack-aging until just prior to use and
kept in a closed container while on the respirator between uses.
13.3 Chemical warning properties
13.3.1 A substance has adequate warning properties when its odor, taste or irritation effects are
detectable and persistent at concentrations at or below the exposure limit.
13.3.2 Supplied-air respirators should be used for protection against gases and vapors with inadequate
warning properties. Where supplied-air respirator use is not feasible, e.g., because of limited mobility,
remote or inadequate air supply, or portable breathing air sources are not usable, and
the provisions of
ANSI Z88.2-1992, 7.2.2.2m are met, air-purifying respirators can be used.
The site occupational health coordinator and the respirator coordinator should be informed of each
situation where air-purifying respirators are used with chemicals having inadequate warning properties.
13.4 Replacement
13.4.1 A documented replacement schedule for canisters/cartridges should be developed for all uses to
assure the capacity of the canisters/ cartridges is not exceeded.
13.4.2 Replacement schedules may be based upon plant experience for contaminants with warning
properties at or below the exposure limit.
13.4.3 Replacement schedule shall be based upon the expected use time that should not exceed the
capacity of the canister/cartridge. Canister/ cartridge element breakthrough times have been determined
for many chemicals. These breakthrough times are listed in the Haskell Laboratory monograph (Reference
5) on respirator cartridges and may be available from the cartridge manufacturer.
13.4.4 If odor or other warning property of the contaminant is noted prior to the scheduled replacement,
wearers should be instructed to immediately leave the respirator use area and notify supervision. Possible
causes of wearer detection of odor/warning property include:
a. Exceeding cartridge capacity
b. Poor respirator fit
c. Respirator malfunction
d. High airborne contaminant levels
13.4.5 In the U.S., government regulations for certain chemicals, i.e., acrylonitrile, require replacement at
specified times.
13.4.6 High humidity may limit capacity and reduce breakthrough times for organic vapor and certain other
cartridge types. Relative humidity conditions are noted for the breakthrough times in the Haskell
Laboratory monograph. In areas with high humidity, the need for breakthrough times determined under
high humidity conditions should be evaluated.
13.4.7 Concentration of the airborne contaminant temperature and flow (breathing) rate also significantly
affect breakthrough times. However, for most breakthrough tests, 53 or 60 LPM flow rates are used to
simulate moderate/heavy work. If expected plant conditions (humidity, flow rate, concentration) differ
significantly from the breakthrough test conditions listed in the Haskell Laboratory monograph, Haskell
Laboratory should be consulted and additional testing approximating plant use conditions should be
considered.
13.4.8 Very limited work has been done on predicting breakthrough times for mixtures of two or more
airborne contaminants. Generally, one component will tend to displace the other, reducing overall
breakthrough time and capacity. For mixtures, business occupational health coordinators and Haskell
Laboratory should be consulted for guidance and possible testing.
13.4.9 After determining breakthrough times and respirator use for specific jobs, many plants have found
some of the following procedures adequate for canister/cartridge replacement:
a. Replace after each use or shift.
b. Replace when respirator is returned to central cleaning facility.
c. Instruct wearer to replace cartridge after specified use period. Color coding (red dot, blue dot, etc.)
or otherwise dating cartridge during dispensing so use interval can be easily audited in the field has
been effective at some sites.
13.4.10 Regeneration of organic vapor cartridges with proper quality controls is probably not economically
feasible at most locations, but may be considered for special situations such as a remote (non-U.S.)
location. If considered, a quality control system should be approved by management prior to
implementation.
Appendix A—Respirator compliance plan Example
Appendix B
The recommended isoamyl acetate and saccharin qualitative fit tests are the result of considerable
research and have been thoroughly validated. Both the isoamyl acetate and the saccharin fit tests confirm
that a good fit is obtained between the respirator facepiece and the face. Particle-removing cartridges or
masks are required for the saccharin fit test, whereas organic vapor cartridges are required for the isoamyl
acetate fit test. After the fit test has been done, the facepiece can be used with any type of cartridges that
may be required to remove workplace contaminants, without invalidating the fit test.
With quantitative fit-testing, collection of a representative sample from in-side the facepiece is necessary
for accurate results. Incomplete mixing of the contaminated air that leaks into the facepiece can lead to
significant sample bias, both over- and underestimating the fit factor seen. To reduce this effect, the
sample collection point inside the facepiece should be located at a point midway between the nose and
mouth. The probe needs to extend into the facepiece for at least 1/4 inch. Avoid locating the probe directly
in front of the inhalation valve. An acceptable alternative is to collect a sample from a small chamber
located outside the respirator and over the exhalation valve (exhalation valve sampling).
B.1 Qualitative fit testing
B.1.1 Description
The procedure is based upon the test subject’s detection of leakage of an odorous or irritating challenge
chemical into the mask. Isoamyl acetate (IAA or isopentyl acetate) vapor is used most frequently. (Isoamyl
acetate is available from Matheson, Coleman & Bell, 2909 Highland Ave., Norwood, OH 45212 as
isopentyl acetate, Cat. No. PX-285.)
B.1.1.1 Advantages
a. Qualitative tests are inexpensive.
b. Equipment is simple and easily obtained.
c. Extensive training is not required to perform these tests.
d. Allows testing of wearer’s personal respirator.
B.1.1.2 Disadvantages
a. These tests rely on subjective responses of test subjects who differ in sensitivity to odors or
irritants. However, an odor and taste sensitivity test is conducted with the IAA and saccharin fit tests
to minimize this problem. Responses may, especially in the case of the use of isoamyl acetate or
saccharin, be affected by personal bias or refusal to admit that the odor or taste was detected.
b. No quantitative measure or documentation of fit factor (FF) is provided.
B.1.2 Precautions
Care must be taken to avoid buildup of concentrations of the challenge chemical in the ambient air of the
test area during qualitative testing. This may cause olfactory fatigue and affect results. When the
challenge agent is detected, care must be taken to assure that subsequent tests are not affected by
olfactory fatigue. It is suggested that mask selection, donning, and the odor threshold test be done in an
area separate from the test chamber. Isoamyl acetate ampules, which are available from some vendors,
do not provide a high enough concentration for testing and should not be used.
B.1.3 Specific procedures
B.1.3.1 Odorous vapor test—isoamyl acetate (IAA)
This can be used for all types of respirators that will accommodate organic vapor cartridges. Air-purifying
respirators must be equipped with this type of cartridge for the test. To optimize results from qualitative fit
testing, test subjects should be:
a. Allowed to choose the most comfortable respirator from among several sizes. When a comfortable
fit cannot be obtained, other manufacturers’ respirators should be investigated.
b. Trained in how to don and adjust the respirator, and what is expected of them in the test.
c. Test to assure that they can detect the odor of 1 ppm isoamyl acetate vapor (see paragraph
B.1.3.1.4).
B.1.3.1.1 To make a qualitative test chamber, attach a clear polyethylene bag approximately 24 inches
in diameter and 60 inches long (55-gallon drum liner) to a 23-inch diameter plywood disk, wire ring, or
other suitable enclosure and suspend from the ceiling so the top of the bag is about
7 feet above the floor. When the subject wearing the respirator enters the test chamber, a piece of
absorbent paper containing 0.75 mL of IAA should be attached to the top of the chamber.
B.1.3.1.2 After a two-minute wait the concentration of IAA will equilibrate at about 150 ppm and testing can
begin. A new piece of paper with IAA should be used for each test. During the test the wearer should carry
out exercises for one minute each including normal breathing, deep breathing, turning head from side to
side, nodding head up and down, talking, and finally normal breathing again. If the wearer detects isoamyl
acetate vapor odor during the test, he should readjust the respirator seal to obtain, if possible, a better fit. If
fit adjustments are necessary, the mask shall be taken off before retesting.
Caution:
Before retesting, make sure test subject has recovered from any olfactory fatigue. Do not allow
straps to be pulled so tightly that they are uncomfortable and not typical of regular use conditions. If the
wearer is unable to detect isoamyl acetate odor, the respirator fit is judged to be satisfactory.
B.1.3.1.3 Odor threshold for isoamyl acetate (IAA) vapor varies among individuals. In odor panel studies at
Victoria Plant, 100% of a test panel of 40 detected the odor of isoamyl acetate at a concentration of 5 ppm,
95% at 0.3 ppm, and 65% at 0.06 ppm. When the contaminated air was introduced into a full-face mask
worn by the test subject, 100% of the panel detected the odor at 5 ppm, 82.5% at 1 ppm, 52.5% at 0.3 ppm,
and 20% at 0.06 ppm. The decreased sensitivity may have been due to competing odor from the rubber
facepiece, pressure of the mask on the face, or psychological effects.
B.1.3.1.4 All persons to be tested should be able to detect isoamyl ace-tate odor at about 1 ppm in air. This
should be verified by a preliminary test. An acceptable method of performing the preliminary odor test is to
add 1.0 mL of isoamyl acetate to 800 mL of odor-free water (20-25×C) in a wide mouth jar (approximately 1
L capacity) and shake for one minute. Transfer 0.4 mL of this solution to a second jar containing 500 mL
water at 20-25×C. Shake for one-half minute and allow the mixture to stand un-disturbed for two to three
minutes before use. Place 500 mL of water in two additional jars. Without indicating which jar contains IAA,
shake each jar, remove its lid, and ask the subject if he detects the odor of IAA (banana-like odor). The
concentration will be stable for eight hours. B.1.3.1.5 If the odor threshold is determined in B.1.3.1.4 and
the IAA test is passed in B.1.3.1.2, a fit factor of approximately 100 has been demonstrated.
B.1.3.2 Saccharin fit test for disposable dust respirators
This method utilizes aerosolized saccharin as the challenge chemical; 3M manufacturers a kit that includes
the test solution and nebulizer and hood (Kit No. FT-10). In spite of FDA restrictions on saccharin use,
Haskell Laboratory considers the level of exposure in this procedure to be of ex-tremely low hazard
potential.
B.1.3.2.1 Instructions for use are provided in the 3M kit. Like the isoamyl acetate test, a sensitivity test is
first performed on the subject without a respirator to ensure the subject can detect (taste) low levels of
saccharin. Then the subject wearing a respirator is placed in a hood, and a more concentrated saccharin
aerosol is sprayed into the hood. If the subject tastes the aerosol, the respirator fit is considered
unacceptable.
B.1.3.2.2 The isoamyl acetate test is preferred for most qualitative fit test applications. However, the
saccharin test must be used for disposable dust masks.
B.1.3.3 Special OSHA standards
The IAA and saccharin tests have been allowed as permissible fit tests to the asbestos (29 CFR
1910.1001), lead (29 CFR 1910.1025), benzene (29 CFR 1910.1028), and formaldehyde (29 CFR 1910.1048) standards. Quantitative fit testing is also allowed by these standards. Fit test protocols are
detailed in each individual standard. Note that if the IAA protocol is used for the OSHA formaldehyde
standard, the saccharin test must also be used.
B.2 Quantitative fit testing
B.2.1 Description
This procedure measures the degree of protection provided by a mask by surrounding the test subject with
a stable atmosphere of airborne challenge chemical and measuring the concentrations of challenge
chemical inside the mask using an analytical device.
B.2.1.1 Advantages
a. A quantitative measure of the protection offered by a respirator on specific individuals and
documentation of the FF is provided.
b. An answer independent of test subject’s sense of odor, susceptibility to irritation or personal bias is
provided.
c. A training tool to demonstrate to employees the need for proper use of the respirator and to
demonstrate the protection provided.
d. Quantitative fit testing requires less preparation/setup time when groups require fit testing.
B.2.1.2 Disadvantages
a. Cost. This includes both initial investment and time involved to perform the test.
b. The test equipment operator must receive training in equipment operation and test performance. It
is preferable that the operator perform this function regularly; otherwise retraining may be necessary.
c. Some OSHA guides require three quantitative fit tests.
B.2.1.3 General
Proliferation of varieties of quantitative fit-test procedures is discouraged. Any of those described below is
acceptable for occasional checking of equivocal qualitative fit tests and is a useful training tool.
B.2.1.3.1 During the fit test, the wearer should carry out exercises including normal breathing, deep
breathing, turning the head from side to side, nodding the head up and down, and talking, e.g., reciting the
“Rainbow Passage” or counting backward from 100.
B.2.1.3.2 In the interest of saving time in the quantitative fit-test chamber, qualitative fit-test methods may
be conducted first to eliminate those respirators that will not provide a satisfactory fit.
B.2.2 Specific procedures
Types of equipment now used at SABIC and Conoco locations are listed below. All but one provide
recorder readout. Generally, quantitative fit-test systems provide a controlled, continuously generated
challenge atmosphere to the test chamber.
A system that can operate without chambers, tents, or aerosol generators is the Portacount fit tester (see
paragraph 2.2.2 of this appendix).
B.2.2.1 Oil aerosol
a. Uses a challenge aerosol (not vapor) of polyethylene glycol 400 (PEG 400), and measures
concentration by light scattering.
b. The wide range of usable measurement capability (10
4
_ minimum
detectable
concentration) and high sensitivity permits FF measurements of at least 20,000.
c. High sensitivity and short response time provide clear indications of leakage variation during
inhalation and exhalation.
d. When fitting is done, the best-fitting and most comfortable mask for each employee should be
chosen from the models provided on the site. Generally, the mask that provides the best fit (highest FF) is also the most comfortable. Where two or more masks provide the required protection factor, the
most comfortable mask should be selected.
B.2.2.2 Portacount fit test
a. The TSI Portacount is a portable instrument that uses either a challenge aerosol or ambient air
allowing operation in a variety of locations including field testing.
b. This system is reported to accurately measure fit factors to 1,000 or greater. As a result, it can be
used to assign protection factors up to
100. See ANSI Z88.2-1992, 9.1.1 (acceptance criteria), which requires that the fit factor be at least 10
times greater than the assigned protection factor.
c. The Portacount is available from:
TSI Incorporated
500 Cardigan Road
St. Paul, MN 55164
(612) 483-0900
d. Follow manufacturer’s directions for conducting fit tests.