Dust Sampling Procedures

8/6/2019 Dust Sampling Procedures

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6/10/02 Michigan Tech

PROCEDURES FOR

Respirable Crystalline Quartz Sampling In Metal-

Nonmetal Mines, Developing A Written Respira-

tory Protection Program And Fit Testing

for use by

Michigan Mine Safety & Health Training Program

Michigan Technological University

by

Dave Carlson and Phil Eggerding

June 15, 2002

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o Snug fitting shirt & trousers (no shorts), etc

o No jewelry where there is danger of catching on things

The technician’s equipment should include the following:

o Personal Dust Samplers, chargers, cyclones and cyclone assemblies 6o Personal Dust Sampler Manual 1

o Pre-weighed filter cassettes (includes 1 spare and 1 control) 7 per day

o Calibrated hand-held rotameter (0-5 LPM) – adapted to cyclone 1o Copies of procedures and data forms As Needed

o Pencils & clipboards As Needed

o Tools (mainly flowrate adjusting screw driver) As Neededo Seal-able plastic bags for storing new and used filter cassettes 1

Procedures for laboratory calibration of the hand-held rotameter and personal dust samplersare presented in Appendix 3. Personal sampler rotameters with the complete head assembly and

filter attached should be calibrated in the laboratory once/year. The personal sampler rotameter

should be marked to indicate the bottom-ball position when the flowrate is at 1.7 liters per minute. The hand-held rotameter, which is used for field calibration, will also be calibrated with

the Gilibrator or other primary flowrate standard at least once/year.

When the personal sampler is first placed on the person, the flowrate should be adjusted so

that the bottom of the ball is at the marked position. Note that as the day progresses, the ball

position may indicate an increasing flowrate if filter backpressure increases as particulate

collects, while the actual flowrate may remain at the initial 1.7 liter per minute setting. For this reason, it is not recommended that, under normal conditions, the flowrate be lowered to

return the ball to the 1.7 liter/minute position. Radical changes in ball position, or any indication

of decreasing flowrate should, however, be checked by removing the cyclone grit pot andmeasuring the flowrate with the calibrated external rotameter (see procedure in Appendix 3).

Personal dust samplers should be checked out and maintained at least annually. For thisreason all samplers on loan must be sent back to the Program office by September 15, so this

annual maintenance can be performed.

Protocol for Dust Measurements

The technician will sample up to 5 persons per day. The samplers will be worn by the

persons sampled for the entire “normal” workshift.

Pre-sampling Procedures

1) Always start the day with a freshly-charged sampler

2) Examine all components of the cyclones, and especially the grit pot, to assure that

they are clean and free of dust and dirt

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3) Examine the inner surface of the cyclone to assure that it is free of scoring

4) Examine the external tubing to assure that it is clean and free of leaks; and

5) Examine the clamping and positioning of the cyclone body, vortex finder and cassette

to assure that they are rigid, in alignment, and firmly in contact.

When the person is ready to accept the sampler, the following steps are taken:

1) The head assembly containing the cyclone, cyclone holder, filter cassette and

connecting tubing is mounted on the sampler

2) Complete the form in Appendix 4, Table 1 including:

a. Date

b. Company

c. Mine or Plantd. Technician

e. Control Cassette no.

3) For each person sampled complete the following:

a. Person sampled and Social Security No.

b. Job descriptionc. Sampler no.

d. Filter no.

e. Flowrate

f. Start Timeg. Stop Time

h. Flowrate checks

i. Timeii. Flowrate

4) The “control cassette” mentioned in item 3 is a filter cassette from the same batch as

the others. This cassette should be labeled “control” along with the sampling date.

The control cassette will not be opened or used, but will be returned to the laboratory

for analysis. Any change in the weight of this cassette will be used to correct the

weight increases for the other cassettes from the same batch used to sample dust on

the particular date.

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Placing the Sampler on the Person

1) The sampler is turned on, the rotameter set to 1.7 liters per minute, and the start time

recorded

2) When attaching the sampling head assembly to the person’s clothing, the inlet of thecyclone should face away from the person’s body

3) The person should be instructed not to cover the inlet with a coat or other garment,

and never to allow the cyclone to be inverted (this will invalidate the sample by

contaminating it with course particulate from the grit pot)

4) The person should be told to work as normally as possible, and to let the technician

know about any changes from normal; also if the sampling equipment is causing any

difficulties

5) The person should be told to let the technician know of any unusual interruptions in

production affecting his/her duties, and when and how long the person leaves the

work area

6) The technician must ensure that the instrument is not presenting a safety hazard. The

unit should be placed on the person sampled such that the sampling tubing will not

catch on equipment or other objects

7) The technician must inform the person that the sampler should remain on him/her at

all locations throughout the day and about when and where the sampler will be

removed

8) The technician should check and record the sampler flowrate as frequently as possible

throughout the shift.

Sampling Time

The person must wear the sampler for the entire “normal” work shift so the dust

collected is representative of that for a typical workday.

Monitoring the Sampling Process

The technician must observe the person being sampled on a frequent basis and takenotes. At least 4 times during the shift, the technician should check and record in

Appendix 4, Table 1 the flowrate for each of the samplers in use. The technician should

take notes on:

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1) Activities of the person sampled

2) Mining activity levels (normal mining period, high production period, etc.)

3) Whether or not working conditions and activities are typical (based on discussion

with company persons)

4) Potential dust source(s) in the areas the person worked

5) Dust controls

6) Wind directions – where the dust the person is exposed to is coming from.

Post Inspection Procedures

NOTE! never invert the cyclone before the filter cassette is removed and sealed!

At the end of the sampling day do the following:

1. Check the final flowrate on the rotameter. If the flowrate has changed

considerably from the 1.7 liter/minute setting, also check the flowrateusing an external rotameter attached to the cyclone grit pot. If this is also

off by more than about 0.1 liter/minute, this must be recorded and

discussed with Dave Carlson and with the Company contact person

2. Remove the filter cassette, seal the ends and place it in a seal-able plastic

bag

3. Clean up the instruments and place them on the charger

4. Wash the cyclones with soap and water using care not to scratch internal

surfaces (no brushes), stand them on end and allow them to air dry

5. Follow instructions provided by the analytical laboratory in sending the

cassettes in for final weighing and calculation, completing any forms the

laboratory requires.

Final Report

A final report is presented as in Appendix 4. Once the data and calculations are received

from the laboratory, complete Appendix 4, Table 2 and the entire report. Send one copy to the

Company, one to the technician, one to the Program Manager and one to the Program Clerk.

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APPENDIX 2

Estimating Costs for Conducting Dust Monitoring Program

Dave Carlson will provide a more accurate cost estimate – For preliminary

estimation purposes, the following information may be provided to the Company contact

person:

The cost will be the cost of wages and travel for the technician.

Technician cost will be $45 per hour during work and $35 per hour during travel.

Estimate of Technician Time

At $45 per hour rate ($60 per hour outside Michigan)

• 1 day of full-shift sampling for up to 5 persons sampled

• Add 1 additional day for each group of 5 person’s sampled

• Add ½ day for shipping samples and completing the report

At $35 per hour rate ($50 per hour outside Michigan)

• Travel time

Estimate of Travel costs (motel & meals may be more depending on area)

• Total Miles x 0.365/mile or airline fare

• Meals at $30 to $46 per day depending on location

• Motel at $65 per day

Estimate of Analytical Charges

Estimate about $75 per sample for analysis of the filters to determine the respirable

crystalline quartz content.

Clients will not be charged for supplies and wages for calibrating and maintaining

the samplers. Nor will clients be charged for telephone consultation with Dave Carlson on

the study and results.

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APPENDIX 3

Calibration of Dust Samplers




LABORATORY AND FIELD CALIBRATION OF PERSONAL SAMPLER

Background

A soap film calibrator equivalent to the Gilibrator, which is simply an automated version of the old inverted burette, may be used as a primary standard for flowrate measurement in laboratory

calibration of flow measurement equipment for field use. The principle of the soap film calibrator isquite simple. The personal sampler (with head assembly attached) is connected to the top of avertical cylinder of accurately-known dimensions. When using an inverted burette, the sampler is

attached to the tip (See schematic Figure 1).

Figure 1. Setup for Calibration Using an Inverted Burette Soap Film Calibrater

The cylinder is open to the air on the bottom end. A soap film is started on the bottom of the

cylinder (such as by placing a small dish of soap solution against the bottom) and this soap film

rises to the top as the air moves through the cylinder. Times are recorded when the film passes

marks at know volume positions; for example, when using a 500 ml burette, the times when the film passes the 500 ml and 0 ml marks would be recorded. The flowrate is then calculated from the

known volume between marks (500 ml) and the elapsed time between marks. For the 500 ml (0.5 L)

burette, the calculation would be:

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Flowrate, L/min = 0.5 x 60

Elapsed time, sec

A flowrate of 1.7 L/min is required when sampling respirable dust in metal-nonmetal mines(note that coal mine samplers use a flowrate setting of 2.0 L/min and there are other minor, but

significant, differences in the procedure). For calibration, it is necessary to use a burette that has a

volume of at least 500 ml between timing marks, where the time for the bubble to travel between

marks is long enough to reduce the relative errors in starting and stopping the timer to acceptablelevels. The Gilibrator automatically times the travel of the soap film between two points along the

cylinder and reads the flowrate out on a digital flowmeter. Automatic timing, as done with the

Gilibrator and similar devices, allows smaller cylinders to be used such as those provided by themanufacturers of the automated units.

Calibration of each personal sampler must be done with the head assembly (containing thetype of filter to be used) attached. The sampler is connected through the sampling head assembly to

the top of the flow-measurement cylinder (see Figures 1 and 2). The sampling head assembly causes

a slight pressure drop in the system. This pressure drop is detected by the sampler pump, and the

pump speed automatically increases to maintain a constant flowrate. Experience has shown that the pump rotameter bottom-ball position may indicate a flowrate that is higher than 1.7 L/min, while, in

fact, the flowrate may not have changed at all.

Accurate measurement of the flowrate of air through the sampler is only possible when the

measurement is made at the cyclone inlet where the pressure drop due to flow resistance in the headassembly has no effect. (Note that the measurement could also be made at the pump outlet if a

fitting was available). It is standard calibration practice to connect the flowmeter to the apex of the

cyclone, which becomes the inlet for air to the system when the normal cyclone inlet is blocked(taped over) and the grit pot on the apex is removed. Attachment of the tubing from the flow

measurement device to the apex of the cyclone is necessary because there is no easy way to attach

tubing from the flow measurement device to the inlet.

Rotameters on all samplers and all rotameters used for field calibration should be calibrated

using the Gilibrator or other soap film device to mark the bottom-ball position when the actual

flowrate is 1.7 L/min. Such checks should be made at least annually and more frequently (aboutonce every 200 hours of use) if the samplers are used often.

Laboratory Calibration – Step by Step Procedures Using the Gilibrator

Calibrating a Personal Sampler Using the Gilibrator

Follow the instrument’s operating instructions for adding the bubble solution, connecting thetubing and measuring the flowrate. The flowrate is read out electronically.

Figure 2 is a schematic illustrating the setup for laboratory calibration of the sampler rotameters

using the Gilibrator.

The steps are as follows:

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1) Select the appropriate cylinder based on the manufacturer’s instructions2) Add film solution to the Gilibrator as follows:

a) Open the small bottle of film solution

b) Gently press the bottle outlet tip against the side arm and squeeze to add solution.Press the bottom bulb occasionally to release trapped air

c) Add solution until the bottom rubber bulb is filled and the solution is just below the armInlet3) Wetting the Walls -- The walls of the glass flowmeter must be wet for the film to travel

through the cylinder without rupturing. This can be done by turning the entire flowmeter on

its side to allow the film solution to run out of the bulb and into the enlarged section. Rotate

the flowmeter so that the solution coats the entire inner surface.

Figure 2. Setup for Calibration Using a Gilibrator Soap Film Calibrater

4) Connect the cylinder to the base

5) Open the bottom tubing fitting on the cylinder (air inlet)

6) Connect tubing from the sampling head assembly to the top fitting on the cylinder (air outlet)7) Turn the Gilibrator on

8) Connect the pump to the sampling head assembly

9) Push the soap film starter into the soap solution

10) Record the reading11) When calibration of all samplers is complete, remove the remaining soap solution, rinse the

cylinder out with water and allow it to dry.

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Laboratory Calibration of the Hand-Held Field-Calibration Rotameter Using the Gilibrator

The rotameter to be used for field calibration of the samplers, should be calibrated in the

laboratory to correctly measure the 1.7 L/min flowrate. Leave the system as when calibrating the personal sampler. Set the personal sampler flowrate to 1.70 L/min as determined with the Gilibrator

connected as in Figure 2. Disconnect the Gilibrator from the apex of the cyclone and connect thehand-held rotameter (Figure 3). Mark the bottom ball position on the hand-held rotameter at this 1.7L/min flowrate. This is the position the ball should be at when using the hand-held rotameter to

calibrate personal samplers in metal and non-metal mines.

Figure 3. Setup for Field Calibration Using A Calibrated Rotameter.

Field Calibration of Personal Sampler Rotameters

Field calibration may not always be necessary if experience shows that the sampler rotameters retain their calibration over time. Before field calibration, the sampler should be cleaned

to remove dust inside and out and examined for physical damage and missing parts (switch covers,

screws, etc.). If the rotameter walls appear dirty inside or out, they should be thoroughly cleaned.Low flowrate normally results from a decrease in the efficiency of the pump caused by poor valve

operation or air leaks. If the pump cannot be adjusted to a flowrate greater than 2.0 liters per

minute, it is faulty and the cause should either be found and corrected, or the pump replaced with a properly-working one.

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The setup for field calibration is that shown in Figure 3 using the laboratory-calibratedrotameter along with the sampler and head assembly (including the filter) to be used for sampling.

Perform this procedure in a clean room at the sampling site, if possible, so the filter doesn’t collect

significant amounts of particulate during calibration. The procedure follows:

1. The cyclone inlet is taped over, the grit pot removed, and the rotameter attached

2. Adjust the flowrate so that the calibrated rotameter reads 1.7 L/min. The sampler rotameter ball

should be very close to the position marked during the laboratory calibration. Note any

differences and, if differences persist, it may be necessary to remark the sampler ball position

3. Replace the grit pot and remove the tape covering the inlet. The sampler is now ready for fielduse.

While sampling, as the day progresses, the filter picks up particulate and the resistance toflow of the sampled air through the filter increases. If this increase is significant, the sampler

rotameter may indicate that the flowrate has increased, although this may not be the case. Therefore,

if either a dramatic increase or a decrease in flowrate is indicated by the sampler rotameter, performthe field calibration again and readjust the flowrate to 1.7 L/min. Record this in your notes and keep

a close eye on the sampler -- it may be necessary to replace the pump with a freshly charged one.

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Appendix 4

Generic Report To Company

Developed by


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Results from

Dust Measurement Survey

at

Company

Conducted by:

Technician Name


Houghton, MI 49931

Date

Questions Should be Directed Either to Technician or To:

David H. Carlson

Manager, Mine Safety & Health Training Program

Geological and Mining Engineering and Sciences Dept.Michigan Technological University

Houghton, MI 49931

Phone – 906/487-2453email – [email protected]

Technician’s Signature Date

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mailto:[email protected]







INTRODUCTION

On date(s), dust sampling was performed at Company name. The employees and occupations

sampled were selected in conversations between Michigan Tech and company personnel. Dust samplers

were placed on number Company employees to obtain full workshift dust exposure measurements.

While the readings accurately represent operating conditions and worker activities at the time

the measurements were made, translating the results into employee exposure over time is only

accurate to the extent that worker activities and operating conditions during sampling were typical of

normal conditions at the Company. Conversations with Company employees indicate that the person

activities and conditions during sampling:

were not typical for the persons sampled

were typical for the persons sampled

were not typical for the following persons and/or measurements.

Person

Sampled

Location of

abnormal

activity

Time of

Day

Differences from Normal Working Conditions

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RESULTS

The data collected during sampling are presented in Table 1. These data and the laboratory results for

each of the employees sampled are summarized in Table 2.

PEL Overexposures

The MSHA standard of primary concern in Company name is the 0.1 mg/m3

time-weighted-average

concentration limit for respirable crystalline quartz (RCQ) in the air a person is exposed to. If MSHA cites

the Company for overexposure to the 0.1 mg/m3

RCQ PEL, the company must install all feasible engineering

controls to reduce a person’s exposure to the PEL. Respiratory protection is required when controls are not

feasible, as well as when establishing controls, and during occasional entry into hazardous atmospheres to

perform short-term maintenance or investigations. Whenever respirators are required the Company mustestablish a written respiratory protection program. The MSHA standard which applies (56/57.5005)

incorporates ANSI Z88.2-1969.

Table 2 indicates that number persons are overexposed, need respiratory protection, and that the

Company may need to work with MSHA on additional feasible controls. To use respiratory protection, the

Company needs to have a written respiratory protection program in place. A respiratory protection program

has a number of elements listed in Attachment 1 which is a generic written respiratory protection program.

The company can make arrangements for assistance in preparing the written program, fit testing and

training by contacting Dave Carlson (906/487-2453). Annual Respirator training can be included in

Michigan Tech’s Part 46 and Part 48 annual refresher mine safety training. To schedule fit testing and/or

annual refresher training, contact Dave Carlson also.

CONCLUSION

Questions on this report should be directed to Dave Carlson (906/487-2453). Questions on dust

control should be directed to MSHA’s Industrial Hygienists for this district – Bill Pomroy or George Schorr

in the Duluth, Minnesota District office (phone -- 218/720-5448).

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Table 1. Respirable Dust Sampling Data SheetDate________ Control Cassette # _____

Mine or Plant ___________ Company ________

Pump flow set, L/min _____ Filter Flowrate Checks Technician _______

Sam- Cas- Time Cyclone

Person sampled Job pler sette Sampling Time of Pump, inlet, Comments

Name SS # description no. no. Start Stop Day L/min L/min where wo




Table 1 Continued -- Respirable Dust Sampling Data Sheet

Date________ Control Cassette # _____

Mine or Plant ___________ Company ________

Pump flow set, L/min _____ Filter Flowrate Checks Technician _______

Sam- Cas- Time Cyclone

Person sampled Job pler sette Sampling Time of Pump, inlet, CommentsName SS # description no. no. Start Stop Day L/min L/min where wo




Table 2. Respirable Crystalline Quartz Measurement Results

Date Sampled __________

Mine or Plant __________

s**Control

Filter Resp. and

Cassette Person’s Person’s Person’s Sampling Time Dust, RCQ*, mg/m3 RPP CoNo. Name SS # Occupation Start Stop mg/m3 Meas. PEL Needed? whe

Control Blank None None None None None 0.1 None

* RCQ = Respirable Crystalline Quartz** Note that others with similar duties may also need to be enrolled.




Table 2 Continued. Respirable Crystalline Quartz Measurement Res

Date Sampled __________

Mine or Plant __________

s**Control

Filter Resp. and

Cassette Person’s Person’s Person’s Sampling Time Dust, RCQ*, mg/m3 RPP Co

No. Name SS # Occupation Start Stop mg/m3

Meas. PEL Needed? whe

Control Blank None None None None None 0.1 None

* RCQ = Respirable Crystalline Quartz** Note that others with similar duties may also need to be enrolled..




Appendix 4. Attachment 1

Generic Written Respiratory Protection Program

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Respiratory Protection Program

Mine Name: Mine I.D.#

1. Written Procedures

a. Hazard Identification & Respirator Selection – Air purifying respirators are

designed to protect persons from breathing specific airborne contaminants andoften provide little or no protection against other contaminants. Table RPP1 lists

for each hazard, the respirators this company will use, their limitations, and job

duties/areas of use.

b. Program Administrator -- Respiratory protection programs will be

administered by ____________________________, who has sufficient

knowledge of the subject to properly supervise the program.

2. Employee training

Training time, min ____ to ____ Teaching Method________________________________________________________

Training Materials _______________________________________________________

Evaluation Method _________________________________________________________ Training will be done by ____________________________________________________

Training will cover all affected employees and supervisors. Training will be conducted beforethe worker begins work in the area where the respirator is needed. Training will include:

1. Engineering and administrative controls, order of priority of controls, proper use and

maintenance of these controls2. Reason respirators are required -- explanation of the hazard and its effects (i.e. acute or

chronic)

3. Selection of a respirator -- fit, comfort, one you can breath through.

4. Health conditions that interfere with respirator use5. How long can you wear a respiratory device, how to detect breakthrough, excessive

resistance to flow etc.

6. Types of respirators and limitations of each including N,R, and P and 95, 99 and 100.7. Respirators used at particular site and proper procedures for mounting, care and maintenance

of each

8. Proper fita. No facial hair

b. Medical conditions affecting skin texture

c. Self-fit test

d. Professional fit tests9. Inspection, cleaning/disinfecting and storage – including reusables and throw-aways.

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Table RPP-1. Respirators Used on Mine Site

Hazard Respirator

Manufacturer

Model No. Respirator Limitations Job Duties/Location W




3. Fit-testing

1. All persons required to use a respirator will be fit tested first

2. Annual fit testing to be conducted on (date)___________________ by (person/organizatiionconducting test)____________________________________________________________

3. The test will be conducted by subjecting each person, while wearing the appropriaterespirator, to the following fit test procedure:

___Qualitative Fit Test by one of the following methods:

a. Stannic Chloride Smoke____

b. Bitrex ____

c. Saccharin____

____Quantitative Fit Test - the fit is acceptable if the person, while wearing a fitted

respirator which has been outfitted with a sample port, is subjected to a test atmosphere(usually mineral oil mist) and the concentration of test atmosphere inside the respirator

is negligible.

4. The person will perform exercises while wearing the respirator in the test atmosphere to

determine if the respirator fits. Exercises will simulate at least the work of lifting, bendingover, talking, movement of the head in all directions and exhibiting various facial

expressions.

5. A written record form of the following will be maintained for these employees. (See copy of

record form at end of this RPP):

a. Name of employee tested;

b. Date of testing;

c. Respirator manufacturer, model, style, and size worn;d. Fit-test protocol and the name of the person administering the test;

e. Fit-test results.

6. If during respiratory fit testing, the employee experiences difficulty breathing through therespirator(s), the employee will be evaluated by a physician to determine his/her medical

suitability for wearing a respirator.

4. Respirator cleaning and disinfecting

Users will be trained:A4-12




1. To inspect respirators prior to each use to determine that they are functioning properly

2. To clean and disinfect or replace the respirator on a regular basis according to

manufacturer's recommendations, or after each use if they are used by more than one person. Adequate cleaning and disinfecting facilities will be provided at the following

convenient location______________________________________________________

3. To store respirators in the following convenient, clean and sanitary location

______________________________________________________________

4. For reusable respirators (person) ______________________________ will be trained to

be knowledgeable in the respirator manufacturer recommendations for the use, care andmaintenance of each model of respirator provided by the Company

5. Employees will be instructed as to where and how to obtain new disposable respirators or respirator cartridges when theirs become unusable, unsanitary, or exhibit excessive

breathing resistance or breakthrough. These respirators will be available at the following

locations: ___________________________________________________________________.

___________________________________________________________________

5. Records of actions taken

(See fit testing/training record form at end of this RPP)

1. Records of fit-test which identify:

a. The exact model and size respirator

b. Date of testing

c. The fit-test method and

d. Whether the person passed or failed the test.

2. Records of training provided which include at least:

a. Identification of persons

b. Date of training and

c. Topics covered.

6. A statement of use

1. Assigned respirators will be worn by persons at all times while in the normal work

areas where persons may be overexposed; These areas will be posted “Respirator

Required” and

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2. Work area(s) affected will be periodically checked to ensure that employees are usingrespirators and to check dust controls, employee exposure, and employee stress due to

breathing resistance or heat. The area supervisor will include this check on his/her daily

walk-around inspection.

Procedures to be used for Qualitative Dust Respirator Fit Testing

RPP Training

1. Controls and their order of priority -- examples of engineering and administrativecontrols

2. Reasons respirators are required for the persons being trained

a. Protect health from what? b Remove what from breathing zone?

c. Acute or chronic effect?

d. PPE is considered by MSHA to be for temporary use until feasible controls areinstalled.

3. Selectiona. Use only the correct respirator for the contaminant of concern.

b. Make sure the respirator you select is comfortable -- If not, let your supervisor

know – you may need to select a different type

c. Make sure you don’t need to strain to breathe with the respirator on(1) If you do, ask your supervisor to schedule a medical examination

(2) If medical examination shows you can’t wear a respirator, you may need

to transfer to a different job

4. Health conditions that interfere with respirator use.

a. Heart condition b. Asthma or other breathing condition

c. Claustrophobiad. Contact lenses

e. Eye glass temples

f. Missing teethg. Skullcaps

h. Other

5. How long can you wear a respirator

a. Contaminant break through

b. High breathing resistance

6. Types of respiratorsa. Filtering (air purifying) and air supply

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b. Types of filtering respiratorsc. Types of particulate respirators and classes

(1) N, R, and P and 95, 99, and 100.

(2) Other toxins

(3) Problems caused when the wrong type is used

7. Types used at this site and proper procedures for putting them on -- Read instructions for and demonstrate each type used

8. Proper fit

a. How to get a good fit?(1) Remove all facial hair; cooperate fully during fit testing.

(2) How to self fit-test the respirator each time it is put on

(a) Breathe out with exhaust valve sealed by hand – should feelrespirator lift from face

(b) Breathe in with inhalation valve sealed – respirator should clingwith no leaks

9. How to inspect respirator and how to clean reusable type, how to store respirator.

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SACCHARIN/BITREX FIT TESTS

Items Needed for Test

1. Selection of respirators to be available at site (the selection should include enough of

each type so that each person tested can try one of each and obtain one).2. Filter cartridges to use when fitting non-dust respirators.

3. Saccharin (or Bitrex) fit test kit including:

a. Dilute test solution (to test the person’s sensitivity) and concentrated test solution(for fit testing)

b. Test Hood and collar

c. Dispensers (nebulizers) for dilute and concentrated solutions and spare partsd. Forms to be used as records that people have been fit tested (copy form at end of

this section)

(1) Date(2) Fit person’s name

(3) Type of respirator person is qualified to use (model and serial no)(4) Type of test used

(5) Statement “By my signature, I verify that I did not detect [the sweet

taste of saccharin] [the bitter taste of Bitrex] during any of the actions

required in fit testing me. However, I did taste the test substance

during the sensitivity test” (6) Fit person’s signature

(7) Tester’s name

(8) Tester’s signature.

Room Set up for Qualitative Fit Testing

1. Set up Work Table for materials in fit test area, and a work table in another room or atleast 20 feet away for the sensitivity test

2. Set up hood assemblies

3. Pour about one teaspoonful of weak solution (#1) into nebulizer labeled #14. Pour about one teaspoonful of strong solution (#2) into nebulizer labeled #2

5. Set up all the different types of respirators that Company wants to fit test and supply each

with a dust filter for fit testing using saccharin or Bitrex6. Mirror(s) for fitting respirator.

Conducting Test

1. Bring in subjects ahead of time, show them how to put on a respirator, how it should be

positioned on the face, how to set strap tension and how to determine an acceptable fit

2. Tell them how to select a respirator – hold each chosen facepiece up to the face andeliminate those that obviously do not give an acceptable fit

3. Review the following comfort and fit criteria with each person:

a. Position of mask on the nose b. Room for eye protection

c. Room to talk.

d. Position of mask on face and cheeksA4-16




e. Chin properly placedf. Adequate strap tension, but not too much.

g. Fit across nose bridge

h. Respirator of proper size for distance from nose to chin

i. Tendency of respirator to slip j. Self-observation in mirror

4. Instruct subject on how to conduct self-fit test and have him/her conduct one; also that if it works proceed with the fit test, otherwise the subject may need to select another respirator

5. Allow subjects to select respirators from a sufficient number of models and sizes and to

self-fit test those selected6. Read the material on the following page.

A4-17




SACCHARIN/BITREX FIT TESTS (continued)

Preliminary remarks for test

Saccharin only -- If you’ve used sweetener in the past hour,

postpone taking this test until later. This includes chewing gum,

candy, drinking pop, drinking coffee with sweetener etc.

Bitrex & Saccharin -- Please tell me if you suspect you’re unable to

taste a weak solution. If you’re unable, the test we’re using won’t

work and we’ll need to use another test.

Correct respirator fit is serious business. Wearing an improperly-

fitting respirator is false security, which makes you think you can go intodusty or other areas without serious consequences.

Dust respirators are for dust only. A dust respirator will not filter out

toxic gases. Make sure you’re using the correct respirator.

Persons with facial hair can’t be fit with a respirator, and can’t

legally work in areas where a respirator is required. A caring

supervisor is obliged to send you home if you’re not clean shaven and

need to work in an area requiring a respirator. Repeat court cases haveupheld management’s rights to require persons working in respirator-use

areas to be clean-shaven or sent home.

How we plan to fit test you

1. You’ll first select a comfortably-fitting respirator by holding it up

against your face as it would be when in actual use. This is the

respirator you’re legally authorized to use from now on if theremaining steps in the selection procedure are successful.

2. You’ll put the respirator on and properly adjust the straps. Note

that if you must wear safety glasses or other head-mounted safety

equipment in your work area, you must wear this equipment during

these tests.

A4-18





3. You’ll wear the respirator for at least 5 minutes to determine if it’s

comfortable. You’ll need to talk, walk, turn your head from side to

side and up and down and make other movements that are similar to movements you make during your work in the respirator area of

your workplace.

4. You’re then ready to be fit tested.

5. You’ll put the hood over your head and I’ll blow the test mist into

one of the openings in the front of the hood. I’ll blow in more

test mist every 30 seconds while you’re performing the following

movements for 60 seconds each. During the entire test, you’ll breath through your mouth so you are able to taste any test solution

that gets past the respirator.

a. Normal breathing

b. Deep breathing (if you feel faint, ease up).

c. Turning head from side to side and inhaling in each position.

d. Nodding head up and down and inhaling in the up position.

e. Counting or reading the rainbow passage.f. Grimacing while breathing.

6. If during any of the above exercises you taste the test mist, the

respirator doesn’t fit and will not provide complete protection.

You’ll need to select another respirator and start over.

7. Finally, after you’ve removed the hood, you’ll go to the other end

of the room and while you’re breathing through your mouth, I’ll blow a very weak solution of test mist toward your mouth using 10

squeezes of dispenser bulb. If you taste the test mist now, but did

not taste it with the respirator on, you’re properly fit.

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For your health’s sake, please be honest – if you taste the test mist at

any time while wearing the respirator, stop me immediately and select a

different respirator to start the test over with.

A4-20




STANNIC CHLORIDE SMOKE FIT TESTS

Items Needed for Test

1. Selection of respirators to be available at site

2. Filter cartridges to use when fitting non-dust respirators3. Fit test kit including:

a. Stannic Chloride Smoke Tubes, Squeeze Bulb and Tubing

b. Forms to be used as records that people have been fit tested (copy form at the endof this writeup)

(1) Date

(2) Fit person’s name(3) Type of respirator person is qualified to use (model and serial no)

(4) Type of test used

(5) Tester’s name(6) Tester’s signature

Room Set up for Qualitative Fit Testing

1. Set up Work Table for materials in fit test area, and a work table in another room or at

least 20 feet away for the sensitivity test

2. Adequate ventilation to remove smoke3. A suitable number of repirators of each type so that each person to be tested can try out

each type and select one that is suitable. For disposable respirators, provide a suitable

number dust filtering cartridges for the test. These must be either HEPA or P100 filterswhen using stannic chloride for the test

4. Mirror(s) for fitting respirator.

Conducting Test

Note – The technician must always cover the free end of the smoke

tube with tubing to minimize the likelihood of injury.

1. Bring in subjects ahead of time, show them how to put on a respirator, how it should be positioned on the face, how to set strap tension and how to determine an acceptable fit.

2. Tell them how to select a respirator – hold each chosen facepiece up to the face and

eliminate those that obviously do not give an acceptable fit.

3. Review the following comfort and fit criteria with each person:a. Position of mask on the nose

b. Room for eye protection

c. Room to talk d. Position of mask on face and cheeks

e. Chin properly placed

f. Adequate strap tension, but not too muchg. Fit across nose bridge

h. Respirator of proper size for distance from nose to chin

i. Tendency of respirator to slipA4-21




STANNIC CHLORIDE SMOKE FIT TEST (continued)

j. Self-observation in mirror

4. Instruct subject on how to conduct self-fit test and have him/her conduct one; also that if

it works proceed with the fit test, otherwise the subject may need to select another

respirator 5 Allow subjects to select respirators from a sufficient number of models and sizes and to

self-fit test those selected

6. Conduct sensitivity test as follows (see instructions next page):a. Advise test subjects that the smoke irritates the eyses, lungs, and nasal passages

and keep the eyes shut

b. Carefully direct a small amount of the smoke in the test subject’s direction todetermine that he/she can detect it

c. After detecting the irritant smoke, the subject puts the respirator on and performs

the required self-fit check(s)7. Conduct these tests as on the following pages. The person must still be sensitive after the

fit test or the test results are invalid. Complete the test record for each person that issuccessfully fitted

8. Read the material on the following page

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Preliminary Remarks

Correct respirator fit is serious business. Wearing an improperly

fitting respirator is false security, which makes you think you can go into

dusty or other areas without serious consequences.

Dust respirators are for dust only. Each respirator has a specific

purpose. A dust respirator will not filter out toxic gases. Make sure

you’re using the correct respirator.

Persons with facial hair can’t be fit with a respirator, and can’t

legally work in areas where a respirator is required. A caring

supervisor will feel obliged to send you home if you’re not clean shaven

and need to use a respirator. Repeat court cases have upheld

management’s rights to require persons working in respirator-use areas

to be clean-shaven or sent home.

HOW WE PLAN TO FIT TEST YOU

1. Before you select and put on a respirator, we will need to expose

you to a small amount of the irritant smoke to see if you are

sensitive to it.

2. You will then select the respirator that seems to fit you best

following the procedures below.

3. We will then subject you to irritant smoke with the respirator onand while you are performing certain exercises.

4. Finally we will repeat the exposure to a small amount of irritant

smoke with the respirator off.

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Close your eyes now and I’ll blow some in your direction. Let me know

what effect it has on you.

1. Now that we’ve determined that you are sensitive to the

irritant smoke, you will select a comfortably-fitting respirator

by holding it up against your face as it would be when in

actual use. This is the respirator you’ll be legally

authorized to use from now on if the remaining steps in

the selection procedure are successful.

2. You’ll put the respirator on and properly adjust the straps. Note that if you must wear safety glasses or other head-

mounted safety equipment in your work area, you must wear

this equipment during these tests.

3. You’ll wear the respirator for at least 5 minutes to determine

if it’s comfortable. You’ll need to talk, walk, turn your head

from side to side and up and down and make other

movements that are similar to movements you make during

your work in the respirator area of your workplace.

4. You’ll do a self-fit test before the stannic chloride fit test.

This involves (manufacturer’s recommendations for self-fit

testing) ________________________________________

_________________________________________________

5. If the respirator seems to be OK and to fit your face with no

leaks, you are ready to be fit tested with the stannic chloridesmoke. Remember -- Breathing stannic chloride smoke is

very uncomfortable and will cause you to cough! Also

keep your eyes closed during the test – it burns your eyes!

6. I’ll blow stannic chloride smoke around the edges of your

respirator from about 12 inches distance. If you don’t cough,

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I’ll blow more smoke around your respirator from 9 and then

from 6 inches while you’re performing the following

movements for 60 seconds each.

a. Normal breathing

b. Deep breathing (if you feel faint, ease up).

c. Turning your head from side to side and inhaling in

each position.

d. Nodding your head up and down and inhaling in the up

position.

e. Counting or reading the rainbow passage.

f. Grimacing while breathing.

7. If during any of the above exercises the stannic chloride makes you

cough, the respirator doesn’t fit and will not protect you. You’ll

need to select another respirator and start over.

Since you didn’t cough when subjected to irritant smoke with the

respirator on we’ll need to check your sensitivity to irritant smoke once

more. Close your eyes now and I’ll blow some in your direction again.

Let me know what effect it has on you.

The test indicates that you are still sensitive to the irritant smoke, but

were unaffected with the respirator on. These results indicate that the

respirator fits. Remember, this is the only respirator you are legally

approved to wear. Before you can legally use a different respirator,

another fit test will need to be conducted.

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Respirator Fit Testing Record

This is to certify that ________________________________, social security

number ___________________ has been trained and fitted in the use, limitations,

and maintenance of the following respirator:

Manufacturer__________ Model number__________

Protection against _____________________

using the following protocol.

Bitrex Solution Aerosol ____

Saccharin Solution Aerosol ____

Stannic Chloride Smoke ____

The following test exercises were performed while being tested for at least 60

seconds each.

1. Normal breathing

2. Breathing deeply

3. Turning head from side to side, inhaling in each position

4. Nodding head up and down, inhaling in the up position

5. Counting or reading the rainbow passage

“ I acknowledge that I have received respirator training and have been fit testaccording to the above instructions. By my signature, I verify:

____Saccharin or Bitrex Protocol -- That I did not detect the test solution during

any of the actions required in fit testing me with the respirator on which this

test qualifies me for. I did, however, taste the test solution during the

sensitivity test”.

____Stannic Chloride Protocol – That I did not smell the stannic chloride smoke

with the respirator on and (or) did not need to cough because of it”. I did smellthe smoke when tested for sensitivity with the respirator off.

.

Signature of Person Fit Tested Date

Signature of Tester Date

A4-26




APPENDIX 5

FIT TEST PROCEDURES THAT ARE

ACCEPTABLE TO OSHA

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OSHA Regulations (Standards – 29 CFR)

Fit Testing Procedures (Mandatory). - 1910.134 App A

Standard Number: 1910.134 App A

Standard Title: Fit Testing Procedures (Mandatory).SubPart Number: 1 Subpart Title: Personal Protective Equipment

Appendix A to § 1910.134: Fit Testing Procedures (Mandatory)

Part 1. OSHA Accepted Fit Test Protocols

A. Fit Testing Procedures — General Requirements

The employer shall conduct fit testing using the following procedures. The requirements in this appendix apply to all

OSHA-accepted fit test methods, both QLFT and QNFT.

1. The test subject shall be allowed to pick the most acceptable respirator from a sufficient number of respirator

models and sizes so that the respirator is acceptable to, and correctly fits the user.

2. Prior to the selection process, the test subject shall be shown how to put on a respirator, how it should be

positioned on the face, how to set strap tension and how to determine an acceptable fit. A mirror shall be

available to assist the subject in evaluating the fit and positioning of the respirator. This instruction may not

constitute the subject's formal training on respirator use, because it is only a review.

3. The test subject shall be informed that he/she is being asked to select the respirator that provides the most

acceptable fit. Each respirator represents a different size and shape, and if fitted and used properly, will provide

adequate protection.

4. The test subject shall be instructed to hold each chosen facepiece up to the face and eliminate those that

obviously do not give an acceptable fit.

5. The more acceptable facepieces are noted in case the one selected proves unacceptable; the most comfortable

mask is donned and worn at least five minutes to assess comfort. Assistance in assessing comfort can be given

by discussing the points in the following item A.6. If the test subject is not familiar with using a particular

respirator, the test subject shall be directed to don the mask several times and to adjust the straps each time to

become adept at setting proper tension on the straps.

6. Assessment of comfort shall include a review of the following points with the test subject and allowing the test

subject adequate time to determine the comfort of the respirator:

(a) Position of the mask on the nose

(b) Room for eye protection

(c) Room to talk

(d) Position of mask on face and cheeks

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7. The following criteria shall be used to help determine the adequacy of the respirator fit:

(a) Chin properly placed;

(b) Adequate strap tension, not overly tightened;

(c) Fit across nose bridge;

(d) Respirator of proper size to span distance from nose to chin;

(e) Tendency of respirator to slip;

(f) Self-observation in mirror to evaluate fit and respirator position.

8. The test subject shall conduct a user seal check, either the negative and positive pressure seal checks describedin Appendix B-l of this section or those recommended by the respirator manufacturer which provide equivalent

protection to the procedures in Appendix B-l. Before conducting the negative and positive pressure checks, the

subject shall be told to seat the mask on the face by moving the head from side-to-side and up and down slowlywhile taking in a few slow deep breaths. Another facepiece shall be selected and retested if the test subject fails

the user seal check tests.

9. The test shall not be conducted if there is any hair growth between the skin and the facepiece sealing surface,

such as stubble beard growth, beard, mustache or sideburns which cross the respirator sealing surface. Any type

of apparel which interferes with a satisfactory fit shall be altered or removed.

10. If a test subject exhibits difficulty in breathing during the tests, she or he shall be referred to a physician or other

licensed health care professional, as appropriate, to determine whether the test subject can wear a respirator

while performing her or his duties.

11. If the employee finds the fit of the respirator unacceptable, the test subject shall be given the opportunity toselect a different respirator and to be retested.

12. Exercise regimen. Prior to the commencement of the fit test, the test subject shall be given a description of the fit

test and the test subject's responsibilities during the test procedure. The description of the process shall include a

description of the test exercises that the subject will be performing. The respirator to be tested shall be worn for

at least 5 minutes before the start of the fit test.

13. The fit test shall be performed while the test subject is wearing any applicable safety equipment that may be

worn during actual respirator use, which could interfere with respirator fit.

14. Test Exercises,

(a) The following test exercises are to be performed for all fit testing methods prescribed in this appendix,

except for the CNP method. A separate fit testing exercise regimen is contained in the CNP protocol. The test

subject shall perform exercises, in the test environment, in the following manner:

(1) Normal breathing. In a normal standing position, without talking, the subject shall breathe

normally.

(2) Deep breathing, in a normal standing position, the subject shall breathe slowly and deeply, taking

A5-3




caution so as not to hyperventilate.

(3) Turning head side to side. Standing in place, the subject shall slowly turn his/her head from side to

side between the extreme positions on each side. The head shall be held at each extreme

momentarily so the subject can inhale at each side.

(4) Moving head up and down. Standing in place, the subject shall slowly move his/her head up anddown. The subject shall be instructed to inhale in the up position (i.e., when looking toward the

ceiling).

(5) Talking. The subject shall talk out loud slowly and loud enough so as to be heard clearly by the

test conductor. The subject can read from a prepared text such as the Rainbow Passage, count

backward from 100, or recite a memorized poem or song.

Rainbow Passage

When the sunlight strikes raindrops in the air, they act like a prism and

form a rainbow. The rainbow is a division of white light into many

beautiful colors. These take the shape of a long round arch, with its path

high above, and its two ends apparently beyond the horizon. There is,

according to legend, a boiling pot of gold at one end. People look, but no

one ever finds it. When a man looks for something beyond reach, his

friends say he is looking for the pot of gold at the end of the rainbow.

(6) Grimace. The test subject shall grimace by smiling or frowning. (This applies only to QNFT testing; itis not performed for QLFT)

(7) Bending over. The test subject shall bend at the waist as if he/she were to touch his/her toes. Jogging in

place shall be substituted for this exercise in those test environments such as shroud type QNFT or QLFT units that do not permit bending over at the waist.

(8) Normal breathing. Same as exercise (1).

(b) Each test exercise shall be performed for one minute except for the grimace exercise which shall be

performed for 15 seconds. The test subject shall be questioned by the test conductor regarding the comfort

of the respirator upon completion of the protocol. If it has become unacceptable, another model of respirator shall be tried. The respirator shall not be adjusted once the fit test exercises begin. Any

adjustment voids the test, and the fit test must be repeated.

B. Qualitative Fit Test (QLFT) Protocols

1. General

(a) The employer shall ensure that persons administering QLFT are able to prepare test solutions, calibrate

equipment and perform tests properly, recognize invalid tests, and ensure that test equipment is in proper

working order.(b) The employer shall ensure that QLFT equipment is kept clean and well maintained so as to operate within

the parameters for which it was designed.

2. Isoamyl Acetate Protocol

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Note: This protocol is not appropriate to use for the fit testing of particulate respirators. If used to fit test particulate

respirators, the respirator must be equipped with an organic vapor filter.

(a) Odor Threshold Screening -- Odor threshold screening, performed without wearing a respirator, is intended

to determine if the individual tested can detect the odor of isoamyl acetate at low levels.

(1) Three 1liter glass jars with metal lids are required.

(2) Odor-free water (e.g., distilled or spring water) at approximately 25 deg. C (77 deg. F) shall be

used for the solutions.

(3) The isoamyl acetate (IAA) (also known at isopentyl acetate) stock solution is prepared by adding

1ml of pure IAA to 800 ml of odor-free water in a 1liter jar, closing the jar and shaking for 30

seconds. A new solution shall be prepared at least weekly.

(4) The screening test shall be conducted in a room separate from the room used for actual fit testing.

The two rooms shall be well-ventilated to prevent the odor of IAA from becoming evident in the

general room air where testing takes place.

(5) The odor test solution is prepared in a second jar by placing 0.4 ml of the stock solution into 500

ml of odor-free water using a clean dropper or pipette. The solution shall be shaken for 30 seconds

and allowed to stand for two to three minutes so that the IAA concentration above the liquid may

reach equilibrium. This solution shall be used for only one day.

(6) A test blank shall be prepared in a third jar by adding 500 cc of odor-free water.

(7) The odor test and test blank jar lids shall be labeled (e.g., 1and 2) for jar identification. Labels

shall be placed on the lids so that they can be peeled off periodically and switched to maintain the

integrity of the test.

(8) The following instruction shall be typed on a card and placed on the table in front of the two test

jars (i.e., 1and 2): "The purpose of this test is to determine if you can smell banana oil at a low

concentration. The two bottles in front of you contain water. One of these bottles also contains a

small amount of banana oil. Be sure the covers are on tight, then shake each bottle for two

seconds. Unscrew the lid of each bottle, one at a time, and sniff at the mouth of the bottle. Indicate

to the test conductor which bottle contains banana oil."

(9) The mixtures used in the IAA odor detection test shall be prepared in an area separate from where

the test is performed, in order to prevent olfactory fatigue in the subject.

(10) If the test subject is unable to correctly identify the jar containing the odor test solution, the IAA

qualitative fit test shall not be performed.

(11) If the test subject correctly identifies the jar containing the odor test solution, the test subject may

proceed to respirator selection and fit testing.

(b) Isoamyl Acetate Fit Test

(1) The fit test chamber shall be a clear 55-gallon drum liner suspended inverted over a 2-foot

diameter frame so that the top of the chamber is about 6 inches above the test subject's head. If no

A5-5




drum liner is available, a similar chamber shall be constructed using plastic sheeting. The inside

top center of the chamber shall have a small hook attached.

(2) Each respirator used for the fitting and fit testing shall be equipped with organic vapor cartridges

or offer protection against organic vapors.

(3) After selecting, donning, and properly adjusting a respirator, the test subject shall wear it to the fittesting room. This room shall be separate from the room used for odor threshold screening and

respirator selection, and shall be well-ventilated, as by an exhaust fan or lab hood, to prevent

general room contamination.

(4) A copy of the test exercises and any prepared text from which the subject is to read shall be taped

to the inside of the test chamber.

(5) Upon entering the test chamber, the test subject shall be given a 6-inch by 5-inch piece of paper

towel, or other porous, absorbent, single-ply material, folded in half and wetted with 0.75 ml of pure

IAA. The test subject shall hang the wet towel on the hook at the top of the chamber. An IAA testswab or ampule may be substituted for the IAA wetted paper towel provided it has been

demonstrated that the alternative IAA source will generate an IAA test atmosphere with a

concentration equivalent to that generated by the paper towel method.

(6) Allow two minutes for the IAA test concentration to stabilize before starting the fit test exercises.

This would be an appropriate time to talk with the test subject; to explain the fit test, the importanceof his/her cooperation, and the purpose for the test exercises; or to demonstrate some of the

exercises.

(7) If at any time during the test, the subject detects the banana-like odor of IAA, the test is failed. The

subject shall quickly exit from the test chamber and leave the test area to avoid olfactory fatigue.

(8) If the test is failed, the subject shall return to the selection room and remove the respirator. The

test subject shall repeat the odor sensitivity test, select and put on another respirator, return to the

test area and again begin the fit test procedure described in (b) (1) through (7) above. The process

continues until a respirator that fits well has been found. Should the odor sensitivity test be failed,the subject shall wait at least 5 minutes before retesting. Odor sensitivity will usually have

returned by this time.

(9) If the subject passes the test, the efficiency of the test procedure shall be demonstrated by having

the subject break the respirator face seal and take a breath before exiting the chamber.

(10) When the test subject leaves the chamber, the subject shall remove the saturated towel and returnit to the person conducting the test, so that there is no significant IAA concentration buildup in the

chamber during subsequent tests. The used towels shall be kept in a self-sealing plastic bag to

keep the test area from being contaminated.

3. Saccharin Solution Aerosol Protocol

The entire screening and testing procedure shall be explained to the test subject prior to the conduct of the

screening test.

(a) Taste threshold screening. The saccharin taste threshold screening, performed without wearing a

respirator, is intended to determine whether the individual being tested can detect the taste of saccharin.

(1) During threshold screening as well as during fit testing, subjects shall wear an enclosure about the

head and shoulder's that is approximately 12 inches in diameter by 14 inches tall with at least the

front portion clear and that allows free movements of the head when a respirator is worn. An

A5-6




enclosure substantially similar to the 3M hood assembly, parts # FT 14 and # FT 15 combined, is

adequate.

(2) The test enclosure shall have a 3/4-inch (1.9 cm) hole in front of the test subject's nose and mouth

area to accommodate the nebulizer nozzle.

(3) The test subject shall don the test enclosure. Throughout the threshold screening test, the test

subject shall breathe through his/her slightly open mouth with tongue extended. The subject isinstructed to report when he/she detects a sweet taste.

(4) Using a DeVilbiss Model 40 Inhalation Medication Nebulizer or equivalent, the test conductor

shall spray the threshold check solution into the enclosure. The nozzle is directed away from thenose and mouth of the person. This nebulizer shall be clearly marked to distinguish it from the fit

test solution nebulizer.

(5) The threshold check solution is prepared by dissolving 0.83 gram of sodium saccharin USP in 100ml of warm water. It can be prepared by putting 1ml of the fit test solution (see (b)(5) below) in

100 ml of distilled water.

(6) To produce the aerosol, the nebulizer bulb is firmly squeezed so that it collapses completely, then

released and allowed to fully expand.

(7) Ten squeezes are repeated rapidly and then the test subject is asked whether the saccharin can betasted. If the test subject reports tasting the sweet taste during the ten squeezes, the screening test

is completed. The taste threshold is noted as ten regardless of the number of squeezes actually

completed.

(8) If the first response is negative, ten more squeezes are repeated rapidly and the test subject is againasked whether the saccharin is tasted. If the test subject reports tasting the sweet taste during the

second ten squeezes, the screening test is completed. The taste threshold is noted as twenty

regardless of the number of squeezes actually completed.

(9) If the second response is negative, ten more squeezes are repeated rapidly and the test subject is

again asked whether the saccharin is tasted. If the test subject reports tasting the sweet taste duringthe third set of ten squeezes, the screening test is completed. The taste threshold is noted as thirtyregardless of the number of squeezes actually completed.

(10) The test conductor will take note of the number of squeezes required to solicit a taste response.

(11) If the saccharin is not tasted after 30 squeezes (step 10), the test subject is unable to taste saccharin

and may not perform the saccharin fit test.

Note to paragraph 3. (a): If the test subject eats or drinks something sweet before the screening test, he/she may be

unable to taste the weak saccharin solution.

(12) If a taste response is elicited, the test subject shall be asked to take note of the taste for reference in

the fit test.

(13) Correct use of the nebulizer means that approximately 1ml of liquid is used at a time in the

nebulizer body.

(14) The nebulizer shall be thoroughly rinsed in water, shaken dry, and refilled at least each morning

and afternoon or at least every four hours.

(b) Saccharin solution aerosol fit test procedure.

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(2) The test enclosure shall have a \3/4\ inch (1.9 cm) hole in front of the test subject's nose and mouth

area to accommodate the nebulizer nozzle.

(3) The test subject shall don the test enclosure. Throughout the threshold screening test, the test

subject shall breathe through his or her slightly open mouth with tongue extended. The subject isinstructed to report when he/she detects a bitter taste.

(4) Using a DeVilbiss Model 40 Inhalation Medication Nebulizer or equivalent, the test conductor shall spray the Threshold Check Solution into the enclosure. This Nebulizer shall be clearly

marked to distinguish it from the fit test solution nebulizer.

(5) The Threshold Check Solution is prepared by adding 13.5 milligrams of Bitrex to 100 ml of 5%salt (NaCl) solution in distilled water.

(6) To produce the aerosol, the nebulizer bulb is firmly squeezed so that the bulb collapses

completely, and is then released and allowed to fully expand.

(7) An initial ten squeezes are repeated rapidly and then the test subject is asked whether the Bitrex

can be tasted. If the test subject reports tasting the bitter taste during the ten squeezes, thescreening test is completed. The taste threshold is noted as ten regardless of the number of

squeezes actually completed.

(8) If the first response is negative, ten more squeezes are repeated rapidly and the test subject is againasked whether the Bitrex is tasted. If the test subject reports tasting the bitter taste during the

second ten squeezes, the screening test is completed. The taste threshold is noted as twenty


(9) If the second response is negative, ten more squeezes are repeated rapidly and the test subject isagain asked whether the Bitrex is tasted. If the test subject reports tasting the bitter taste during the

third set of ten squeezes, the screening test is completed. The taste threshold is noted as thirty


(10) The test conductor will take note of the number of squeezes required to solicit a taste response.

(11) If the Bitrex is not tasted after 30 squeezes (step 10), the test subject is unable to taste Bitrex andmay not perform the Bitrex fit test.

(12) If a taste response is elicited, the test subject shall be asked to take note of the taste for reference in

the fit test.

(13) Correct use of the nebulizer means that approximately 1ml of liquid is used at a time in the

nebulizer body.

(14) The nebulizer shall be thoroughly rinsed in water, shaken to dry, and refilled at least each morning

and afternoon or at least every four hours.

(b) Bitrex Solution Aerosol Fit Test Procedure.

(1) The test subject may not eat, drink (except plain water), smoke, or chew gum for 15 minutes

before the test.

(2) The fit test uses the same enclosure as that described in 4.(a) above.

(3) The test subject shall don the enclosure while wearing the respirator selected according to section

1. A. of this appendix. The respirator shall be properly adjusted and equipped with any type

particulate filter(s).

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(1) The test operator shall break both ends of a ventilation smoke tube containing stannic chloride,

and attach one end of the smoke tube to a low flow air pump set to deliver 200 milliliters per

minute, or an aspirator squeeze bulb. The test operator shall cover the other end of the smoke tube

with a short piece of tubing to prevent potential injury from the jagged end of the smoke tube.

(2) The test operator shall advise the test subject that the smoke can be irritating to the eyes, lungs,

and nasal passages and instruct the subject to keep his/her eyes closed while the test is performed.

(3) The test subject shall be allowed to smell a weak concentration of the irritant smoke before the

respirator is donned to become familiar with its irritating properties and to determine if he/she can

detect the irritating properties of the smoke. The test operator shall carefully direct a small amountof the irritant smoke in the test subject's direction to determine that he/she can detect it.

(c) Irritant Smoke Fit Test Procedure

(1) The person being fit tested shall don the respirator without assistance, and perform the required

user seal check(s).

(2) The test subject shall be instructed to keep his/her eyes closed.

(3) The test operator shall direct the stream of irritant smoke from the smoke tube toward the face seal

area of the test subject, using the low flow pump or the squeeze bulb. The test operator shall beginat least 12 inches from the facepiece and move the smoke stream around the whole perimeter of

the mask. The operator shall gradually make two more passes around the perimeter of the mask,

moving to within six inches of the respirator.

(4} If the person being tested has not had an involuntary response and/or detected the irritant smoke, proceed with the test exercises.

(5) The exercises identified in section 1.A. 14. of this appendix shall be performed by the test subjectwhile the respirator seal is being continually challenged by the smoke, directed around the

perimeter of the respirator at a distance of six inches.

(6) If the person being fit tested reports detecting the irritant smoke at any time, the test is failed. The person being retested must repeat the entire sensitivity check and fit test procedure.

(7) Each test subject passing the irritant smoke test without evidence of a response (involuntary

cough, irritation) shall be given a second sensitivity screening check, with the smoke from thesame smoke tube used during the fit test, once the respirator has been removed, to determine

whether he/she still reacts to the smoke. Failure to evoke a response shall void the fit test.

(8) If a response is produced during this second sensitivity check, then the fit test is passed.

C. Quantitative Fit Test (QNFT) Protocols

The following quantitative fit testing procedures have been demonstrated to be acceptable: Quantitative fit testingusing a non-hazardous test aerosol (such as corn oil, polyethylene glycol 400 [PEG 400], di-2-ethyl hexyl sebacate

[DEHS], or sodium chloride) generated in a test chamber, and employing instrumentation to quantify the fit of the

respirator; Quantitative fit testing using ambient aerosol as the test agent and appropriate instrumentation(condensation nuclei counter) to quantify the respirator fit; Quantitative fit testing using controlled negative pressure

and appropriate instrumentation to measure the volumetric leak rate of a facepiece to quantify the respirator fit.

1. General

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(a) The employer shall ensure that persons administering QNFT are able to calibrate equipment and perform

tests properly, recognize invalid tests, calculate fit factors properly and ensure that test equipment is in

proper working order.

(b) The employer shall ensure that QNFT equipment is kept clean, and is maintained and calibratedaccording to the manufacturer's instructions so as to operate at the parameters for which it was designed.

2. Generated Aerosol Quantitative Fit Testing Protocol

(a) Apparatus.

(1) Instrumentation. Aerosol generation, dilution, and measurement systems using particutates (cornoil, polyethylene glycol 400 [PEG 400], di-2-ethyl hexyl sebacate [DEHS] or sodium chloride) as

test aerosols shall be used for quantitative fit testing.

(2) Test chamber. The test chamber shall be large enough to permit all test subjects to perform freelyall required exercises without disturbing the test agent concentration or the measurement

apparatus. The test chamber shall be equipped and constructed so that the test agent is effectively

isolated from the ambient air, yet uniform in concentration throughout the chamber.

(3) When testing air-purifying respirators, the normal filter or cartridge element shall be replaced witha high efficiency particulate air (HEPA) or P100 series filter supplied by the same manufacturer.

(4) The sampling instrument shall be selected so that a computer record or strip chart record may be

made of the test showing the rise and fall of the test agent concentration with each inspiration and

expiration at fit factors of at least 2,000. Integrators or computers that integrate the amount of test

agent penetration leakage into the respirator for each exercise may be used provided a record of

the readings is made.

(5) The combination of substitute air-purifying elements, test agent and test agent concentration shall

be such that the test subject is not exposed in excess of an established exposure limit for the testagent at any time during the testing process, based upon the length of the exposure and the

exposure limit duration.

(6) The sampling port on the test specimen respirator shall be placed and constructed so that noleakage occurs around the port (e.g., where the respirator is probed), a free airflow is allowed into

the sampling line at all times, and there is no interference with the fit or performance of the

respirator. The in-mask sampling device (probe) shall be designed and used so that the air sample

is drawn from the breathing zone of the test subject, midway between the nose and mouth andwith the probe extending into the facepiece cavity at least 1/4 inch.

(7) The test setup shall permit the person administering the test to observe the test subject inside thechamber during the test.

(8) The equipment generating the test atmosphere shall maintain the concentration of test agent

constant to within a 10 percent variation for the duration of the test.

(9) The time lag (interval between an event and the recording of the event on the strip chart or

computer or integrator) shall be kept to a minimum. There shall be a clear association between the

occurrence of an event and its being recorded.

(10) The sampling line tubing for the test chamber atmosphere and for the respirator sampling port

shall be of equal diameter and of the same material. The length of the two lines shall be equal.

(11) The exhaust flow from the test chamber shall pass through an appropriate filter (i.e., high

efficiency particulate filter) before release.

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(12) When sodium chloride aerosol is used, the relative humidity inside the test chamber shall not

exceed 50 percent.

(13) The limitations of instrument detection shall be taken into account when determining the fit factor.

(14) Test respirators shall be maintained in proper working order and be inspected regularly for

deficiencies such as cracks or missing valves and gaskets.

(b) Procedural Requirements.

(1) When performing the initial user seal check using a positive or negative pressure check, thesampling line shall be crimped closed in order to avoid air pressure leakage during either of these

pressure checks.

(2) The use of an abbreviated screening QLFT test is optional. Such a test may be utilized in order toquickly identify poor fitting respirators that passed the positive and/or negative pressure test and

reduce the amount of QNFT time. The use of the CMC QNFT instrument in the count mode is

another optional method to obtain a quick estimate of fit and eliminate poor fitting respirators before going on to perform a full QNPT.

(3) A reasonably stable test agent concentration shall be measured in the test chamber prior to testing.

For canopy or shower curtain types of test units, the determination of the test agent's stability may be established after the test subject has entered the test environment.

(4) Immediately after the subject enters the test chamber, the test agent concentration inside the

respirator shall be measured to ensure that the peak penetration does not exceed 5 percent for a

half mask or 1percent for a full facepiece respirator.

(5) A stable test agent concentration shall be obtained prior to the actual start of testing.

(6) Respirator restraining straps shall not be over-tightened for testing. The straps shall be adjusted by

the wearer without assistance from other persons to give a reasonably comfortable fit typical of

normal use. The respirator shall not be adjusted once the fit test exercises begin.

(7) The test shall be terminated whenever any single peak penetration exceeds 5 percent for half

masks and 1percent for full facepiece respirators. The test subject shall be refitted and retested.

(a) Calculation of fit factors

(i) The fit factor shall be determined for the quantitative fit test by taking the ratio of the average chamber

concentration to the concentration measured inside the respirator for each test exercise except thegrimace exercise.

(ii) The average test chamber concentration shall be calculated as the arithmetic average of the concentration

measured before and after each test (i.e., 7 exercises) or the arithmetic average of the concentration

measured before and after each exercise or the true average measured continuously during the respirator sample.

(iii) The concentration of the challenge agent inside the respirator shall be determined by one of the following

methods:

(A) Average peak penetration method means the method of determining test agent penetration into therespirator utilizing a strip chart recorder, integrator, or computer. The agent penetration is determined by

an average of the peak heights on the graph or by computer integration, for each exercise except the

grimace exercise. Integrators or computers that calculate the actual test agent penetration into the

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respirator for each exercise will also be considered to meet the requirements of the average peak

penetration method.

(B) Maximum peak penetration method means the method of determining test agent penetration in the

respirator as determined by strip chart recordings of the test. The highest peak penetration for a givenexercise is taken to be representative of average penetration into the respirator for that exercise.

(C) Integration by calculation of the area under the individual peak for each exercise except the grimaceexercise. This includes computerized integration.

(D) The calculation of the overall fit factor using individual exercise fit factors involves first converting the

exercise fit factors to penetration values, determining the average, and then converting that result back toa fit factor. This procedure is described in the following equation:

Overall Fit Factor = Number of Exercises

1/ff 1+1/ff 2+1/ff 3+1/ff 4+1/ff 5+1/ff 6+1/ff 7+1/ff 8

Where ff 1, ff 2, ff 3, etc. are the fit factors for exercises 1, 2, 3, etc.

(9) The test subject shall not be permitted to wear a half mask or quarter facepiece respirator unless a

minimum fit factor of 100 is obtained, or a full facepiece respirator unless a minimum fit factor of 500 is obtained.

(10) Filters used for quantitative fit testing shall be replaced whenever increased breathing resistance is

encountered, or when the test agent has altered the integrity of the filter media.

3. Ambient aerosol condensation nuclei counter (CNC) quantitative fit testing protocol. The ambient aerosol

condensation nuclei counter (CNC) quantitative fit testing (Portacount TM) protocol quantitatively fit testsrespirators with the use of a probe. The probed respirator is only used for quantitative fit tests. A probed

respirator has a special sampling device, installed on the respirator, that allows the probe to sample the air from

inside the mask. A probed respirator is required for each make, style, model, and size that the employer usesand can be obtained from the respirator manufacturer or distributor. The CNC instrument manufacturer, TSI

Inc., also provides probe attachments (TSI sampling adapters) that permit fit testing in an employee's own

respirator. A minimum fit factor pass level of at least 100 is necessary for a half-mask respirator and a minimumfit factor pass level of at least 500 is required for a full facepiece negative pressure respirator. The entirescreening and testing procedure shall be explained to the test subject prior to the conduct of the screening test.

(a) Portacount Fit Test Requirements.

(1) Check the respirator to make sure the sampling probe and line are properly attached to the

facepiece and that the respirator is fitted with a particulate filter capable of preventing significant

penetration by the ambient particles used for the fit test (e.g., NIOSH 42 CFR 84 series 100, series99, or series 95 particulate filter) per manufacturer's instruction.

(2) Instruct the person to be tested to don the respirator for five minutes before the fit test starts. This

purges the ambient particles trapped inside the respirator and permits the wearer to make certain

the respirator is comfortable. This individual shall already have been trained on how to wear therespirator properly.

(3) Check the following conditions for the adequacy of the respirator fit: Chin properly placed;

Adequate strap tension, not overly tightened; Fit across nose bridge; Respirator of proper size tospan distance from nose to chin; Tendency of the respirator to slip; Self-observation in a mirror to

evaluate fit and respirator position.

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(4) Have the person wearing the respirator do a user seal check. If leakage is detected, determine the

cause. If leakage is from a poorly fitting facepiece, try another size of the same model respirator,

or another model of respirator.

(5) Follow the manufacturer's instructions for operating the Portacount and proceed with the test.

(6) The test subject shall be instructed to perform the exercises in section 1. A. 14. of this appendix.

(7) After the test exercises, the test subject shall be questioned by the test conductor regarding the

comfort of the respirator upon completion of the protocol. If it has become unacceptable, another

model of respirator shall be tried.

(b) Portacount Test Instrument.

(1) The Portacount will automatically stop and calculate the overall fit factor for the entire set of

exercises. The overall fit factor is what counts. The Pass or Fail message will indicate whether or not the test was successful. If the test was a Pass, the fit test is over.

(2) Since the pass or fail criterion of the Portacount is user programmable, the test operator shallensure that the pass or fail criterion meet the requirements for minimum respirator performance in

this Appendix.

(3) A record of the test needs to be kept on file, assuming the fit test was successful. The record mustcontain the test subject's name; overall fit factor; make, model, style, and size of respirator used;

and date tested.

4. Controlled negative pressure (CNP) quantitative fit testing protocol. The CNP protocol provides an

alternative to aerosol fit test methods. The CNP fit test method technology is based on exhausting air from atemporarily sealed respirator facepiece to generate and then maintain a constant negative pressure inside the

facepiece. The rate of air exhaust is controlled so that a constant negative pressure is maintained in the

respirator during the fit test. The level of pressure is selected to replicate the mean inspiratory pressure thatcauses leakage into the respirator under normal use conditions. With pressure held constant, airflow out of the

respirator is equal to airflow into the respirator. Therefore, measurement of the exhaust stream that is required

to hold the pressure in the temporarily sealed respirator constant yields a direct measure of leakage airflow intothe respirator. The CNP fit test method measures leak rates through the facepiece as a method for determiningthe facepiece fit for negative pressure respirators. The CNP instrument manufacturer Dynatech Nevada also

provides attachments (sampling manifolds) that replace the filter cartridges to permit fit testing in an employee's

own respirator. To perform the test, the test subject closes his or her mouth and holds his/her breath, after which

an air pump removes air from the respirator facepiece at a pre-selected constant pressure. The facepiece fit isexpressed as the leak rate through the facepiece, expressed as milliliters per minute. The quality and validity of

the CNP fit tests are determined by the degree to which the in-mask pressure tracks the test pressure during the

system measurement time of approximately five seconds. Instantaneous feedback in the form of a real-time pressure trace of the in-mask pressure is provided and used to determine test validity and quality. A minimum

fit factor pass level of 100 is necessary for a half-mask respirator and a minimum fit factor of at least 500 is

required for a full facepiece respirator. The entire screening and testing procedure shall be explained to the test

subject prior to the conduct of the screening test.

a) CNP Fit Test Requirements.

(1) The instrument shall have a non-adjustable test pressure of 15.0 mm water pressure.

(2) The CNP system defaults selected for test pressure shall be set at — 15 mm of water (-0.58 inches

of water) and the modeled inspiratory flow rate shall be 53.8 liters per minute for performing fittests.

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(Note: CNP systems have built-in capability to conduct fit testing that is specific to unique work rate, mask, and

gender situations that might apply in a specific workplace. Use of system default values, which were selected to

represent respirator wear with medium cartridge resistance at a low-moderate work rate, will allow inter-test

comparison of the respirator fit.)

(3) The individual who conducts the CNP fit testing shall be thoroughly trained to perform the test.

(4) The respirator filter or cartridge needs to be replaced with the CNP test manifold. The inhalationvalve downstream from the manifold either needs to be temporarily removed or propped open.

(5) The test subject shall be trained to hold his or her breath for at least 20 seconds.

(6) The test subject shall don the test respirator without any assistance from the individual who

conducts the CNP fit test.

(7) The QNFT protocol shall be followed according to section 1.C. 1. of this appendix with anexception for the CNP test exercises.

(b) CNP Test Exercises.

(1) Normal breathing. In a normal standing position, without talking, the subject shall breathenormally for 1minute. After the normal breathing exercise, the subject needs to hold head straight

ahead and hold his or her breath for 10 seconds during the test measurement.

(2) Deep breathing. In a normal standing position, the subject shall breathe slowly and deeply for

1minute, being careful not to hyperventilate. After the deep breathing exercise, the subject shall

hold his or her head straight ahead and hold his or her breath for 10 seconds during test

measurement.

(3) Turning head side to side. Standing in place, the subject shall slowly turn his or her head from side

to side between the extreme positions on each side for 1minute. The head shall be held at eachextreme momentarily so the subject can inhale at each side. After the turning head side to side

exercise, the subject needs to hold head full left and hold his or her breath for 10 seconds during

test measurement. Next, the subject needs to hold head full right and hold his or her breath for 10seconds during test measurement.

(4) Moving head up and down. Standing in place, the subject shall slowly move his or her head up

and down for 1minute. The subject shall be instructed to inhale in the up position (i.e., when

looking toward the ceiling). After the moving head up and down exercise, the subject shall holdhis or her head full up and hold his or her breath for 10 seconds during test measurement. Next,

the subject shall hold his or her head full down and hold his or her breath for 10 seconds during

test measurement.

(5) Talking. The subject shall talk out loud slowly and loud enough so as to be heard clearly by the

test conductor. The subject can read from a prepared text such as the Rainbow Passage, count

backward from 100, or recite a memorized poem or song for 1minute. After the talking exercise,

the subject shall hold his or her head straight ahead and hold his or her breath for 10 secondsduring the test measurement.

(6) Grimace. The test subject shall grimace by smiling or frowning for 15 seconds.

(7) Bending Over. The test subject shall bend at the waist as if he or she were to touch his or her toes

for 1minute. Jogging in place shall be substituted for this exercise in those test environments suchas shroud-type QNFT units that prohibit bending at the waist. After the bending over exercise, the

subject shall hold his or her head straight ahead and hold his or her breath for 10 seconds during

the test measurement.

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(8) Normal Breathing. The test subject shall remove and re-don the respirator within a one-minute

period. Then, in a normal standing position, without talking, the subject shall breathe normally for

1minute. After the normal breathing exercise, the subject shall hold his or her head straight ahead

and hold his or her breath for 10 seconds during the test measurement. After the test exercises, thetest subject shall be questioned by the test conductor regarding the comfort of the respirator upon

completion of the protocol. If it has become unacceptable, another model of a respirator shall be

tried.

(c) CNP Test Instrument.

(1) The test instrument shall have an effective audio warning device when the test subject fails to holdhis or her breath during the test. The test shall be terminated whenever the test subject failed to

hold his or her breath. The test subject may be refitted and retested.

(2) A record of the test shall be kept on file, assuming the fit test was successful. The record mustcontain the test subject's name; overall fit factor; make, model, style and size of respirator used;

and date tested.

Part XX. New Fit Test Protocols

A. Any person may submit to OSHA an application for approval of a new fit test protocol. If the application meets

the following criteria, OSHA will initiate a rulemaking proceeding under section 6(b)(7) of the OSH Act todetermine whether to list the new protocol as an approved protocol in this Appendix A.

B. The application must include a detailed description of the proposed new fit lest protocol. This application must

be supported by either:

1. A test report prepared by an independent government research laboratory (e.g., Lawrence Livermore

National Laboratory, Los Alamos National Laboratory, the National Institute for Standards and

Technology) stating that the laboratory has tested the protocol and had found it to be accurate andreliable; or

2. An article that has been published in a peer-reviewed industrial hygiene journal describing the protocoland explaining how test data support the protocol's accuracy and reliability.

C. If OSHA determines that additional information is required before the Agency commences a rule making

proceeding under this section, OSHA will so notify the applicant and afford the applicant the opportunity to

submit the supplemental information. Initiation of a rulemaking proceeding will be deferred until OSHA hasreceived and evaluated the supplemental information.

[63 FR 20098, April 23, 1998]

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