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NEBOSH

International Diploma in Occupational Health and Safety

UNIT IB: International management of hazardous agents


in the workplace

Hazardous chemicals – engineering controls and


IB3
Element IB3:

personal protective equipment


IB3 1.1 Contents

3.0 Learning outcomes 3

3.1 Ventilation 4

General (dilution) ventilation 4

Local exhaust ventilation (LEV) 5

Applications / principles of capture 5

LEV system components 7

Factors reducing effectiveness of LEV 19

Visual, qualitative inspection of LEV 19

Measurements for assessing the performance of LEV 20

LEV thorough examination and test 23

3.2 Personal protective equipment (PPE) 26

The choice and effectiveness of PPE / RPE 26

Assessment of personal protective equipment 27

Wearer acceptability / comfort 28

Fit 28

Training  29

Respiratory protective equipment (RPE) 31

Types of respirators and breathing apparatus 31

Suitability / selection of RPE 38


Assigned protection factor (APF) 44

Storage and maintenance of RPE 51

Skin and eye protection 54

Skin protection 54

Choosing and using protective gloves  55

Eye / face protection 59

Body protection 62

General considerations when choosing PPE 63

General training for PPE 64

Practical measures to ensure correct use of PPE 65

References 66

© Astutis Ltd Element IB3: Hazardous chemicals – engineering controls and personal protective equipment
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3.0 3.0 Learning outcomes

On completion of this element, candidates should be able to:

XX Explain the purpose and operation of local exhaust ventilation and dilution ventilation
including assessing and maintaining effectiveness.

XX Explain the various types of personal protective equipment (PPE) available for use with
hazardous chemicals, their effectiveness, and the factors to consider in their selection.

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3.1 3.1 Ventilation

This section discusses general (or dilution) ventilation which manages the flow of air into
and out of a working area to provide fresh air and dilute contaminated air, and local exhaust
ventilation (LEV) systems which remove respiratory hazards from the air so that workers do not
breathe them in.

General (dilution) ventilation

General ventilation:

XX provides fresh air

XX removes excess heat or provides heat to maintain a comfortable temperature

XX dilutes and removes offensive odours

XX dilutes any contaminants caused by workplace activities.

General ventilation or ‘dilution’ ventilation is a term used to define the flow of air into and
out of a working area, so that any contaminants are diluted by adding some fresh air. It can be
provided by:

XX Natural ventilation which relies on wind pressure and temperature differences to move
fresh air through a building and is usually not fully controllable.

XX ‘Forced’ or mechanical ventilation which uses mechanical supply and/or extraction to


provide fresh air and is controllable.

Planned natural ventilation through roof ventilators

Mechanical
Infiltration of ventilation
air through using fans in
cracks and the wall or
poorly fitted roof or ducted
windows, doors, air inlet and
roof, panels, etc. extract systems

Planned ventilation through open doors, windows and through wall ventilators

Figure 3.1: General ventilation

© Astutis Ltd Element IB3: Hazardous chemicals – engineering controls and personal protective equipment
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Local exhaust ventilation (LEV)

Applications / principles of capture

A local exhaust ventilation (LEV) system takes contaminants (dusts, mists, gases, vapour or
fumes) out of the air so that they can’t be breathed in. Properly designed LEV:

XX Takes contaminated air away from a specific contaminated source.

XX Minimises the air entering the operator’s breathing zone.

XX Cleans the air (if necessary) and gets rid of the contaminants safely.

LEV might not be the right control solution when:

XX There are a large number of widely-spaced sources.

XX The source is large and LEV is impossible to apply over the entire source.

XX The source position is not fixed.

XX The source emits relatively small amounts of contaminant (which is not toxic).

XX The contaminant is offensive but not harmful.

For LEV to work effectively the hood has to be carefully matched to the contaminated air source
that needs to be controlled. Consideration needs to be given to the following:

XX Particle size of contaminant clouds: the size of particles determines whether they are
‘inhalable’ or ‘respirable’.
XX Visibility of particle clouds: there may be particles that cannot be seen:
• Respirable dust clouds are practically invisible to the naked eye.
• Inhalable dust clouds are partially visible.
• Mist and fume clouds are more visible than the equivalent concentration of dust.

XX Movement of particles in air: particles in contaminant clouds move with the air in which
they are suspended, for example:
• Larger particles (> 100 μm) travel some distance if ejected at high speed but settle
out quickly.
• Larger particles, even of low-density material such as plastic dust, fall out of the
air easily.
• Medium sized particles (100 μm) settle out of the air near the process (depending on
the strength of local air movement).
• Smaller particles float and remain suspended in the air for longer and move with air
currents. This means that fine dust will be carried a long way from the source, making
dust control difficult.

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LEV needs to remove both suspended inhalable particles and intercept the larger particles.
For some processes, such as on a woodworking saw, LEV collects and transports both dust
and chips.

Abrasive or corrosive particles: some particles are more abrasive than others (silica, for
example) and some are more chemically active (acids, for example), and may attack the LEV
system components. This may severely restrict the selection of materials used to construct the
LEV system.

Sticky dust, mist and condensate: if a particulate is sticky or likely to condense, the LEV design
needs to take account of this. A heavy condensate can progressively block ducts. In these
circumstances, the design of the system needs to incorporate drain points for condensates,
and access points to ease inspection and cleaning.

Flammable or combustible substances: many organic and metal dusts, such as zinc, are
combustible and LEV systems need to reduce the chances of ignition and cope with a possible
dust explosion.

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LEV system components

The basic components of an LEV system are:

XX An inlet, for example: a hood or enclosure, to collect and contain the contaminant close
to its source.

XX Ductwork, to convey the contaminant away from the source.

XX A filter / air-cleaner to remove the contaminant from the extracted air-stream


(Note: the filter should normally be located before the fan).

XX A fan or other air-moving device to provide the necessary airflow.

XX Further ductwork to an outlet or exhaust which discharges the cleaned air to the outside
atmosphere at a suitable point.

Air mover

Discharge

Air cleaner
Ducting

Hood

Inlet

Figure 3.2: Local exhaust ventilation system

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Inlet

Hood selection and design are critical to the performance of an LEV system, and must match the
process, the source, production and how the operator carries out the process. Successful LEV
systems contain, capture or receive the contaminant cloud within the LEV hood and conduct
it away. The greater the degree of enclosure of the source, the more likely it is that control will
be successful.

More effective Type of enclosure Description Example(s)

Full enclosure Process is completely Glove box


enclosed

Room enclosure / The operator and the Abrasive-blasting


Enclosing room process are enclosed rooms

Paint-spraying
booth

Partial enclosure Contains the process Fume cupboard


with openings for
material and/or
operator access

Less effective

Table 3.1: Types of enclosure

Hood face

( b ) Receiving hood
Hood
face Hood face

( a ) Enclosing hood
( c ) Capturing hood

Figure 3.3: Types of hood

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Enclosing hoods are the most effective type of hood. Examples are shown in Table 3.1.

Receiving hoods are designed to take advantage of the speed and direction of the contaminant
cloud as generated by the process. A canopy hood over a hot process is a classic receiving
hood, taking advantage of thermal currents to take the contaminant away from the workplace.
Receiving hoods can be fixed or moveable.

Capturing hoods (captor or capture hood) are the most common type of LEV hood. A capturing
hood has to generate sufficient airflow at and around the source to ‘capture’ and draw in the
contaminant-laden air. Hoods can be fixed or moveable. Examples include rim/lip extraction
(slot), downdraught tables or benches and low volume high velocity (LVHV) hood, a canopy
with lip extraction.

LEV systems work effectively when the airborne contaminant cloud is contained, received or
captured by the hood. The effectiveness of LEV can be judged by:

XX How much the hood constrains the contaminant cloud.

XX How well the LEV induced airflow carries the contaminant cloud into the system.

XX How little of the contaminant cloud enters the process operator’s breathing zone.

WATCH. LISTEN. DO

If you don't work with LEV it can be difficult to visualise what


they look like and how they work. Go online to find out more
about LEV capturing hoods and have a go at working out if you
think a particular hood is effective or not.

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Ducting

Designers should take the following points into account with regard to ductwork:

XX Keep the design as simple as possible.

XX Provide smooth-bore ductwork and an obstruction-free interior for particle extraction.

XX Have a sufficiently high air velocity to keep particles suspended in the air stream, while
low enough to keep noise levels acceptable.

XX Route ductwork to minimise noise nuisance.

XX Keep duct pressures negative within the building, as far as possible.

XX Have the minimum number of bends and junctions to minimise the flow resistance.

XX When changes of direction are necessary, they should be made smoothly.

XX Junctions and changes of section should also be smooth.

XX T-junctions should not be used.

XX Incorporate tapered sections when the duct cross-section needs to change.

XX Provide drainage points at any low points in an LEV system for aerosols, mists, or
substances that may condense or support combustion.

XX Provide access points as appropriate for cleaning and to clear blockages.

XX Minimise the length of horizontal run for transport of particles.

XX Depending on the expected range of temperatures, the ducting should accommodate


thermal expansion and contraction.

Taking into account the physical conditions and chemical nature of the contaminants, ducting
materials should:

XX Give the best resistance consistent with cost and practicability.

XX Have sufficient strength and supporting structures to withstand likely wear and tear.

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Duct (transport) velocities

The air velocity through the duct must be high enough to keep particles suspended in the air
stream (larger particles will require higher velocities). It should also be high enough to suspend
and remove particles that settle out when the system stops. The designer needs to avoid
deposition in any part of the ductwork. This is a particular problem:

XX in long horizontal runs of ducting

XX at low points

XX at junctions where the duct diameter increases

XX after junctions or bends

XX when conveying large and small particles together, such as woodworking dusts.

Accumulation of settled particles reduces the diameter and shape of the duct, increases
resistance and reduces the airflow in the system. Settled particles are difficult to re-entrain in
the airflow and can lead to duct blockage and fire risk from flammable materials.

Type of contaminant Indicative duct


velocity (m/s)

Gases and non-condensing vapours 5

Condensing vapours, fume and smoke 10

Low or medium density, low moisture content dusts (plastic dust, 15


sawdust), fine dusts and mists

Process dust (cement dust, brick dust, wood shavings, grinding dust) Around 20

Large particles, aggregating and damp dusts (metal turnings, moist Around 25
cement dust, compost)

Table 3.2: Recommended minimum duct velocities

© Astutis Ltd Element IB3: Hazardous chemicals – engineering controls and personal protective equipment
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Filter / air cleaner

The purpose of the air cleaner is to remove the contaminant from the contaminated air. It is
situated before the fan to protect the fan from the contaminant.

Particle collectors

Particle collectors are the most common group of air cleaning devices associated with LEV
systems.

Fabric filters

These are suitable for dry dusts. Dusty Cleaned


air out
air passes one way through a fabric
layer that is flexible and porous. The
fabric may be constructed and treated
to carry electrostatic forces which help
attract and retain dust. Particles are Air passes
removed by: through filter
bags, leaving
dust on the
XX Impaction: particles, larger than outside

the weave, meet the surface of Dirty Filter bags


air in (woven or
the filter. felted)

XX Impingement: medium-size
Dust collection
particles meet the fibres within bag or hopper

the filter weave.

XX Diffusion: small particles are


attracted towards the fibres. Figure 3.4: Dust bag particulate filter

The main ways to clean filter bags are:

XX mechanical shaking

XX reverse airflow

XX pulse-jet.

The cost of the filter material is a major expense. It is also an operating cost, as filters need
periodic replacement before they fail, which is normally between one and four years.

© Astutis Ltd Element IB3: Hazardous chemicals – engineering controls and personal protective equipment
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Cyclones Clean air

Cyclones consist of a circular chamber, tapered at


the bottom. Dusty air feeds at a tangent into the top
of the cyclone and swirls around the chamber. This
Dirty
throws particles out to the wall by centrifugal action. air

The particles’ velocities decrease
and they fall to a


collection hopper at the base of the cyclone. Cleaned
air passes through a central outlet in the top of the
Dirty air swirls around
cyclone. The larger the particle, the easier it is for a outside of chamber
throwing off dust
cyclone to remove it from the air.
Dust falls into
collection hopper

Figure 3.5: Cyclone

Electrostatic precipitators Voltage control box

Electrostatic precipitators are suitable


Cleaned
for fine dusts, but unsuitable for heavy air out

contamination. They give dust and fume


particles an electrical charge and attract Dirty
air in
them onto collecting surfaces with an Collector
plates
opposite charge. Cleaned air flows out of Electrode
wires
the device. There are two classes of design: Dust
collection
hopper
XX Pipe or tube: a high-voltage wire lies
along the axis of a grounded tube.

XX Parallel plate: a series of high- Figure 3.6: Electrostatic precipitator


voltage wires lie between a series of
grounded metal plates.

© Astutis Ltd Element IB3: Hazardous chemicals – engineering controls and personal protective equipment
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Scrubbers

‘Scrubbing’ means wetting particles and washing them out of a contaminant cloud. There are
numerous designs of scrubbers:
Cleaned
gas
Venturi scrubbers: 
the most common
form of scrubber. Dusty air passes
through a narrow venturi throat, which
has a water injection. The conditions
Separator
in the throat are highly turbulent. The
water separates into small droplets that
collide with the dust particles. A cyclone Water injection

separates the droplets to produce a


sludge containing the dust. Cleaned air Dirty gas Venturi
Settling tank
inlet Make-up
passes through a central outlet in the water
Sludge
top of the cyclone.

Figure 3.7: Venturi Scrubber

Self-induced spray collectors: dusty air is drawn under a baffle in a water trough. The dust
impacts on droplets and also on water in the trough. A ‘spray eliminator’ or ‘drift eliminator’
separates water droplets from the cleaned air. The contaminant settles out as sludge at
the bottom of the collector. To avoid bacterial infection and consequent bad odours, spray
collectors need regular cleaning. There may be a legionella risk. 


Wet cyclone scrubbers: dusty air enters a cyclone collector that has a centrally located water
spray directed outwards. The cyclone separates the droplets, producing sludge from the dust.
Cleaned air passes through a central outlet in the top of the cyclone.

Packed tower scrubbers: for substances that mix with water, a tower is filled with packing to
provide a large surface area. Water or a reagent solution flows in at the top of the tower and
contaminated air enters at the bottom. Trickling fluid absorbs the contaminant and cleaned air
emerges at the top. To avoid bacterial infection and consequent bad odours, tower scrubbers
need regular cleaning. There may be a legionella risk.

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Air cleaners for gases and vapours

The technologies used include:

Destruction methods: thermal oxidation (incineration) or flare, for example. Gases or vapour
are destroyed before discharge by burning or thermal oxidation. Thermal oxidiser units can be
fitted with heat recovery that partially offsets the fuel costs.

Recovery methods: adsorption, for example. Contaminated air passes through filters that
remove gases and vapours. Activated carbon filters are the most common. Air is usually filtered
of particles before being passed through a carbon filter. Regeneration of carbon filters and
solvent recovery is feasible, but recovery becomes viable only when the solvent usage is high.
Impregnated carbons are able to absorb specific chemicals. Typical disadvantages include:

XX A frequent need to change the filter.

XX The filter fails suddenly when saturated.

XX Carbon can develop ‘hot spots’ that need heat detectors and fire-extinguishing systems.

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Fan

The fan is the most common air mover. It draws air and contaminant from the hood, through
ductwork to discharge. There are five general categories of fan:

XX Propeller, such as general or dilution ventilation.

XX Axial not suitable for dusts.

XX Centrifugal are the most commonly used fans for LEV systems.

XX Turbo exhauster.

XX Compressed-air-driven air mover.

The efficiency and noise characteristics of fans vary significantly between fan types, sizes,
speed and how they are used. The power required from the fan, and its efficiency, vary with
the volume flow rate. For a particular application, many factors need consideration for fan
selection. These include:

XX The type of substance in the contaminant cloud.

XX Flammability or combustibility.

XX The airflow required.

XX The system resistance characteristics.

XX The fan pressure characteristics.

XX Space limitations.

XX The method of mounting the fan, and the type of drive.

XX The operating temperature.

XX Acceptable noise levels.

Propeller fans

Propeller fans are often used for general or dilution ventilation.


They are light and inexpensive to buy and run, with a wide range of
volume flow rates. However, they will not produce much pressure
and operate best against low resistance.

The fan blades are of sheet material (metal or plastic) mounted in a plate or cage and on a hub
that is attached directly to the shaft of an electric motor, or belt driven. Generally, they are
unsuitable for ducted systems with a moderate resistance or with particle filters.

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Axial fans

Axial fans are not suitable for dusts. They are


compact, do not develop high pressures and cannot
overcome the resistance to flow that many industrial
applications require.

The impeller fan blades are on a rotating hub mounted


in a short cylindrical casing. The fan is in the duct. Unless
the contaminant is flammable or corrosive, the motor is
also in the duct.

Centrifugal fans

Centrifugal fans are the most commonly used fans


for LEV systems. They generate large differences
in pressure and can produce airflows against
considerable resistance.

The impeller fan blades are mounted on a back plate,


often within a scroll casing. Air is drawn into the centre
of the impeller along the line of the drive shaft. The air is
ejected at a tangent to the impeller.

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Outlet or exhaust

Whether or not it has been cleaned, extracted air must not re-enter the building or enter
other buildings unless the contaminant has reached negligible concentrations. Discharged air
must leave the discharge duct at a high enough speed to make sure it is dispersed. Discharge
is normally via a ‘stack’.

Stack siting

Buildings have a surrounding ‘boundary layer’ of air. The objective is to discharge air beyond
the boundary layer, and prevent it entering recirculation eddies. The discharge point should be
located well above the highest point of a building. A weather cowl and deflector baffles may be
required to prevent the wind shearing (preventing any discharge from the stack) and the entry
of vermin.

Stack design 


Gas leaves a discharge stack and rises due to its momentum and buoyancy. Once its energy has
decayed and the air cooled to ambient temperature, the plume is carried by the prevailing wind.

Increases in the velocity of the final discharge can be achieved by putting a tapered nozzle on
the outlet. Taller stacks prevent the mixing of discharged air with the boundary layer air, but
these may not gain planning approval.

The use of LEV can result in neighbour complaints regarding fan noise, odour and visible fume.
Waste arising from contaminated filters or water scrubbers must be disposed of responsibly.

Environmental Regulators may have stipulations for stack height. In addition, the employer
may need permission from the environmental regulator for discharges to the atmosphere.

EXAM QUESTIONS

Outline the main design features of the following parts of a Local Exhaust Ventilation
(LEV) system:

(a) inlet / hood (2 marks)


(b) ducting (3 marks)
(c) fan (2 marks)
(d) outlet / exhaust (3 marks)

Remember that you can have a go at answering these questions


online AND the answers expected by the examiners will also be
revealed!

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Factors reducing effectiveness of LEV

The following factors can reduce the effectiveness of LEV:

XX Poor design: inappropriate inlet for type and size of contaminant cloud, or underpowered
fan unable to capture contaminated air.

XX Poor use: system not switched on when needed, or inappropriate positioning of moveable
hood.

XX Unauthorised modification: can imbalance a system and adversely affect air flows.

XX Inadequate maintenance: damaged ducting, congested filters and damaged fan blades
will compromise the effectiveness of the LEV.

XX Changes of work activity: generating more contaminant than the LEV was designed to
cope with.

Visual, qualitative inspection of LEV

How often the LEV system should be checked depends on how complicated the system is, how
likely it is to fail, and the consequences if it does.

Regular maintenance inspections should be made of the following areas:

XX Moving parts that may wear, such as fan bearings or filter shakers.

XX Non-moving parts, such as hoods, ductwork and seals (which can suffer physical or
chemical damage and wear).

XX Parts that deteriorate with use, such as filters or flexible ducting.

XX Items that need regular attention, such as filters that need replacing, or removing sludge
from a wet scrubber.

This may involve daily operator checks and periodic checks by managers.

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Measurements for assessing the performance of LEV

A variety of qualitative and quantitative methods can be used to assess the performance of LEV.

Qualitative assessment techniques

Observation 


The ‘dust lamp’ or ‘Tyndall illumination’ makes fine particles visible. The ‘Tyndall effect’ is the
forward scattering of light. This is commonly seen when a shaft of sunlight entering a building
shines through mist, dust or fume in the air. The ‘dust lamp’ reproduces this effect by producing
a powerful parallel beam of light (see Figure 3.7). It shows the density and movement of particle
clouds in its path. The lamp should be moved to illuminate different parts of the cloud and
indicate the full cloud size and behaviour.

LEV hood

Dust/aerosol
Lamp cloud

5° to 15°

Black Shield
background

Worker Eye or camera

Figure 3.8: A dust lamp

Figure 3.9: Soldering shown without a dust lamp and with a dust lamp

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Other forms of observational assessment can be made using smoke from pellets, smoke tubes
or smoke generators.

These can:

XX Show the size, velocity and behaviour of airborne contaminant clouds.

XX Identify capture zones and boundaries.

XX Confirm containment within a hood.

XX Identify draughts, their direction and size.

XX Show the general movement of air.

Cameras, fibre-optic camera and boroscopes can be used for internal LEV examinations. 


Quantitative assessment methods

Quantitative methods produce a reproducible measurement of performance. Measurements


alone do not provide direct evidence of control effectiveness, but the records are available for
future comparison, as benchmarks.

Inlet

Face or capture velocity. See Figure Face of booth divided into Meter placed in
imaginary rectangles midpoint of each rectangle
3.10.

Ducts

Transport (duct) velocity is measured


in a straight section of duct, well
downstream of bends and other
turbulence sources. The duct velocity
must be sufficient to keep the particles
airborne, otherwise particles may
Air velocity is measured at
settle out in the ductwork and affect a series of positions across
the face of the booth
the overall efficiency of the system.
The actual dust velocity required is
determined by considering the nature
of the particles that the system is
Figure 3.10: Measurement of face velocity on a fume cupboard
handling such as size and density.

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An anemometer, such as a thermal anemometer or hot wire, velometer or a pitot-static tube,
could be used. The choice of instrumentation is governed by the air velocity in the duct (a
thermal anemometer is more suitable if this is less than 3ms-1).

An anemometer responds to the cooling effect of airflow and the pitot-static tube measuring,
via a pressure gauge, velocity pressure which can then be converted to velocity.

Fan/air mover

Measures can be taken of: fan direction and speed, the pressure difference across the fan, and
the volume flow rate. A big difference in pressure across the fan (i.e. resistance) indicates that
the system will not be as efficient.

Air cleaner

Filters: pressure differential across the filter.

Wet scrubber: pressure difference at the inlet and outlet, and the water pH if relevant to the
scrubbing performance.

Air sampling

Additionally, air sampling may be carried out as proof of the efficiency of a LEV system and
effective control of the contaminant where the hazard and potential risk is great. (See Element IB4).

Air sampling may also include testing emission levels from the exhaust, for example: volatile
organic compounds (VOCs).

When carrying out testing all instruments should be calibrated, and where there may be
flammable atmospheres intrinsically safe instruments should be used.

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LEV thorough examination and test

The ILO Code of Practice on Safety in the use of chemicals at work recommends that engineering
control measures should be thoroughly examined and tested at suitable or specified intervals
to ensure that they are continuing to perform as originally intended.

The intervals and content of the thorough examination should be in accordance with national
laws or national or international standards and should be specified taking into account the
extent of the risk in the event of failure of the control measure.

In the USA the American Conference of Governmental Industrial Hygienists (ACGIH) advocate
an initial test at the time of initial installation to verify the volumetric flow rate(s), and to
obtain other information which can be compared with the original design data. Thereafter the
performance of the system should be checked periodically. If there have been no alterations
to the system, this can be done by static pressure measurements and close visual inspection.
Whenever alterations have been made to the system, a new initial test is required.

In the UK a thorough examination is required at least every 14 months, and more frequently if
the system is used to control exposure to specified hazardous substances.

The results of each thorough examination and test should be compared with the assessment
of risks and control measures, and any defects disclosed as a result of the examination or test
should be remedied as soon as possible, or within such time as the examiner directs.

The thorough examination should be undertaken by a competent person. This can be

XX an outside contractor

XX a competent employee of the LEV owner (the employer).

A record of the examination and test must be kept available for at least five years from the date
they were carried out at the workplace containing the LEV system.

The aim is to make sure it works well and protects the employees.

The thorough examination includes airflow and pressure measurements, checks on control
effectiveness and, possibly, exposure measurement. It tests the LEV against the performance
recorded in the commissioning report.

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A thorough examination and testing of LEV can be considered to comprise three stages:

XX Stage 1: a thorough visual examination to verify the LEV is in efficient working order, in
good repair and in a clean condition.
XX Stage 2: measure and examine the technical performance to check conformity with
commissioning or other sources of relevant information.

XX Stage 3: assess whether the control of worker exposure is adequate.

LEV examiners need the appropriate equipment, such as Pitot tubes, a smoke generator, a dust
lamp, an anemometer and, sometimes, equipment for air sampling.

The examiner judges whether the system is contributing effectively to controlling exposure to
substances hazardous to health and produces a prioritised plan for any actions.

A comprehensive report should include:

XX The name and address of the employer responsible for the LEV.

XX The date of examination and test.

XX The date of the last thorough examination and test.

XX The identification and location of the LEV, and the process and hazardous substance
concerned.
XX The conditions at the time of the test and whether this was normal production or special
conditions.
XX A simple diagram of the LEV layout and location, with test points.

XX The condition of the LEV system including hood serial numbers and, where appropriate,
photographs of relevant parts.
XX Its intended operating performance for adequately controlling the hazardous substance
and whether it is still achieving the same performance.
XX The methods used to make a judgement of performance and what needs to be done
to achieve that performance, for example visual, pressure measurements, airflow
measurements, dust lamp, air sampling, tests to check the condition and effectiveness
of the filter.
XX The results of any air sampling relevant to LEV performance.

XX Comments on the way operators used the LEV.

XX Comments on system wear and tear and whether components may need repair or
replacement before the next annual test.
XX The name, job title and employer of the person carrying out the examination and test.

XX The signature of the person carrying out the examination and test.

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XX The details of any minor adjustments or repairs carried out to make the LEV system
effective.

Note. The employer needs to know about critical defects immediately and should not wait for
the report.

WEB LINKS

Safety in the use of chemicals at work – ILO Code of Practice


www.ilo.org/safework/info/standards-and-instruments/codes/WCMS_107823/lang--
en/index.htm

Local exhaust ventilation (LEV) workplace fume and dust extraction webpages from
the UK’s Health and Safety Executive (HSE)
www.hse.gov.uk/lev/index.htm

EXAM QUESTIONS

(a) Outline why it is important to measure transport (duct) velocity when


assessing the efficiency of a local exhaust ventilation (LEV) system. (2 marks)

(b) Outline the methods that can be used to measure transport velocity
in an LEV system. (5 marks)

(c) Identify other measurements that can be used to determine if the LEV
system is working as designed. (3 marks)

Remember that you can have a go at answering these questions


online AND the answers expected by the examiners will also be
revealed!

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3.2 3.2 Personal protective equipment (PPE)

PPE includes all equipment (including clothing affording protection against the weather) which
is intended to be worn or held by a person at work and which protects that person against
one or more risks to his health or safety, for example, gloves, eye protection and respiratory
protective equipment.

An employer cannot ask for money from an employee for PPE, whether it is returnable or not.
This includes agency workers if they are legally regarded as employees.

If employment has been terminated and the employee keeps the PPE without the employer’s
permission, then, as long as it has been made clear in the contract of employment, the employer
may be able to deduct the cost of the replacement from any wages owed.

The choice and effectiveness of PPE / RPE

PPE should be regarded as the last resort to protect against risks to health and safety.
Engineering controls and safe systems of work should be considered first. This is because:

XX PPE protects only the person wearing it, whereas measures controlling the risk at source
can protect everyone at the workplace.

XX Maximum levels of protection are seldom achieved with PPE in practice and the actual
level of protection is difficult to assess.

XX If RPE is used incorrectly, or is badly maintained, the wearer is unlikely to receive adequate
protection.

XX RPE is uncomfortable to wear and is an intrusion into normal activities.

XX RPE may interfere with work.

Effective protection is only achieved by:

XX suitable PPE

XX correctly fitted PPE

XX maintained PPE

XX properly used PPE.

In addition, PPE may restrict the wearer to some extent by limiting movement or visibility.

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Assessment of personal protective equipment

In order to assess which types of PPE are suitable to protect against exposure to substances,
careful consideration of all the hazards should be made, including the following factors:

The job itself and the risks: for example, if there is a risk of low oxygen concentrations,
breathing apparatus may have to be chosen. Other factors to consider are, for example, the
physical effort needed to do the job, how long the PPE needs to be worn, and the requirements
for visibility and communication.

The environment: the surrounding conditions, such as the weather if working outside, heating,
noise, atmospheric conditions, etc.

The person: the health of the person wearing the PPE and its ergonomic effects. PPE made
of certain materials should not be issued to workers if they are known to cause allergies, for
example: powder lined latex gloves. Heavy or bulky suits can cause or make worse existing
musculoskeletal problems and cause thermal comfort problems. The aim should be to choose
PPE which will give maximum protection while ensuring minimum discomfort to the wearer, as
uncomfortable equipment is unlikely to be worn properly.

Product safety standards

Any PPE bought must meet relevant national / international product safety standards. In
Europe, for example, the equipment must be ‘CE’ marked and comply with the requirements
of the PPE Directive (89/686/EEC). The CE marking signifies that the PPE satisfies certain
basic safety requirements and in some cases will have been tested and certified by an
independent body.

Type and level of protection required

The risk assessment will indicate the type of protection required from:

XX type of substance and its nature, such as corrosive, toxic, etc.

XX form of the substance

XX route of entry into the body

XX concentration of the substance.

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Compatibility

If there is more than one risk present it may be necessary to wear more than one item of
PPE. In these cases the different items of PPE must be compatible with each other, that is,
all items should adequately control the risks. For example, some half mask respirators and
goggles worn together may cause a poor fit, leading to increased risk of eye injury and/or
respiratory exposure.

Individual issues

Workers are owed a special ‘duty of care’. It is important to take into consideration any
individual issues such as:

XX Existing health issues, such as eczema, asthma, etc.

XX Young workers.

XX Pregnant workers.

XX Workers with religious principles, such as Sikh’s wearing turbans.

XX Workers wearing, for example, contact lenses or prescription glasses, which may be
affected by the PPE.

Wearer acceptability / comfort

When choosing PPE, consultation with employees is essential either through worker
representatives or directly with employees. There is a better chance of PPE being used
effectively if it is accepted by each wearer.

Fit

There will be considerable differences in the physical dimensions of different workers.


However, PPE is designed for the ‘average person’, usually with some amount of adjustment.
Unfortunately many workers do not know how to adjust the equipment correctly and this can
increase the risk.

More than one type or size of PPE may be needed and the required range may not be available
from a single supplier. It is often best to give a choice of several correctly specified types of RPE
to wearers so they can choose the one they like.

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Training

Employers are required to provide suitable information, instruction and training for their
employees, to enable them to make effective use of the PPE provided to protect them against
workplace hazards to their health and safety.

Workers must be trained in:

XX The proper use of PPE.

XX How to correctly fit and wear it.

XX What its limitations are.

Managers and supervisors must also be aware of why PPE is being used and how to use it
properly. People involved in maintaining, repairing and testing the equipment and in its
selection for use will also need training.

The extent of the instruction and training will vary with the complexity and performance of the
equipment. For PPE which is simple to use and maintain, such as safety helmets, some basic
instructions to the users will be all that is required.

On the other hand, the safe use of respiratory protective equipment will depend on an
adequate understanding of the principles behind it. The instruction and training should include
both theory and practice.

Theoretical training should include:

XX An explanation of the risks present and why PPE is needed.


XX The operation, performance and limitations of the equipment.

XX Instructions on the selection, use and storage of PPE. Written operating procedures, for
example, permits to work involving PPE should also be explained.
XX Factors which can affect the protection provided by the PPE such as other protective
equipment, personal factors, working conditions, inadequate fitting, and defects, damage
and wear.
XX Recognising defects in PPE and arrangements for reporting loss or defects.

Practical training should include:

XX Practice in putting on, wearing and removing the equipment.

XX Practice in inspection and, where appropriate, testing of the PPE before use.
XX Practice in how to maintain PPE, which can be done by the user, such as cleaning and the
replacement of certain components.
XX Instruction in the safe storage of equipment.

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WEB LINKS

ILO advice on personal protective clothing and equipment


www.ilo.org/sector/Resources/training-materials/WCMS_161776/lang--en/index.htm

European Directive 89 / 686 / EEC – personal protective equipment


osha.europa.eu/en/legislation/directives/workplaces-equipment-signs-personal-
protective-equipment/osh-related-aspects/34

Personal protective equipment (PPE) advice from the UK’s Health and Safety Executive
(HSE)
www.hse.gov.uk/toolbox/ppe.htm

Personal protective equipment information booklet from the US Occupational Safety


and Health Administration (OSHA)
www.osha.gov/Publications/osha3151.html

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Respiratory protective equipment (RPE)

Respiratory protective equipment (RPE) is designed to protect the wearer against inhalation of
hazardous substances in the workplace air.

Types of respirators and breathing apparatus

There are two broad categories of RPE: respirators and breathing apparatus (BA). Respirators
work by filtering contaminants out of the air so that the wearer breathes clean air. BA works by
delivering a supply of breathable air from an uncontaminated source.

The key factors in selecting appropriate RPE are:

XX The level of oxygen present in the air to be breathed.

XX The presence of toxic chemicals that may pose an imminent risk to life.

Only BA should be specified where the level of oxygen in the air is less than 20% or if there is
an imminent risk to life.

Respiratory Protective Equipment


(RPE)

Respirators Breathing Apparatus


Filter out contamination in the air in the Provides uncontaminated air from an
workplace before it is inhaled by the wearer independent source

Simple Power
Fresh air hose Powered airline Self-
filtering assisted
BA BA contained BA
respirators respirators

Figure 3.11: Main categories of RPE

Both types of RPE are available with a range of different face pieces, but there are some
important limitations:

Masks: these are tight-fitting face pieces (filtering face pieces, half and full-face masks). They
rely on having a good seal with the wearer’s face. They can be part of both respirators and BA.

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Hoods, helmets, visors, blouses, suits: these are loose-fitting face pieces which rely on enough
clean air being provided to the wearer to prevent contaminant leaking in. They are only used on
fan-powered respirators and/or air-fed equipment.

Respirators: filtering existing air Breathing Apparatus: oxygen

Figure 3.12: Types of respirator and breathing apparatus

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Respirators

Simple filtering respirators: range


from simple disposable paper dust
masks providing a low level of ori-
nasal (nose and mouth) protection
against larger particulates (dust)
to cartridge type respirators which
Figure 3.13: An ori-nasal may be half mask (ori-nasal) or Figure 3.14: A disposable
particulate dust mask paper dust mask
full-face mask and may use one or
with filter
two exchangeable filter cartridges
that must be carefully specified
for known contaminants.

Power assisted respirators: use hoods, helmets, visors or blouses


with a battery powered filter unit. They achieve a high level of
protection as in addition to the filtration unit the positive airflow
to the breathing zone prevents the ingress of contaminated air.
The cooling effect of the airflow can also improve worker comfort.

Types of filter Figure 3.15: A power


assisted respirator
with mask
There are three main types of filters:

Particle filters

These filters trap and hold particles (dust, mist, fume, smoke, micro-organisms) from the air
flowing through them. Large particles are easier to trap than small ones. These filters can be
used against both solid particles and liquid mists and droplets. However, particle filters do not
trap gases or vapours including organic liquid mists and sprays, or give any protection against
oxygen-deficient atmospheres.

Gas/vapour filters

These filters are designed to remove gases or vapours as specified by the manufacturer. They
do not protect against particles, or oxygen-deficient atmospheres. 
These filters have a limited
capacity for removing gases/vapours, so after a time, the gas or vapour will ‘breakthrough’ to
the RPE wearer’s respiratory system.

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Combined filters

These filters are available for situations where protection is needed against both particles and
specific gas or vapour – for example, an organic vapour filter and a high efficiency particle filter.

Substance Filter Type Colour

Particulate, such as dust, fume P White

Organic gases and vapours (BP>65oC) A Brown

Organic gases and vapours (BP<65oC) AX Brown

Inorganic gases (not CO) B Grey

Sulphur dioxide, acid gases and vapours E Yellow

Ammonia & organic ammonia derivatives K Green

Mercury Hg + name Red – white


of chemical

Oxides of nitrogen NO Blue – white

Specific substances SX Violet (violet – white when


combined with a P filter)

Table 3.3: Filter types

Filter efficiency

P1: low efficiency: used with PF4 respirators. Do not use against fume unless 
the manufacturer
can guarantee protection.

P2: medium efficiency: used with PF10 respirators. Not to be used against fume unless the
manufacturer can guarantee protection.

P3: high efficiency: used with PF20 or PF40 respirators.

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Gas and vapour filters

The classification of gas and vapour filters is based on how much of the specified contaminant
they can hold in a laboratory test at set conditions.

XX Class 1: low capacity.

XX Class 2: medium capacity.

XX Class 3: high capacity.

Therefore an A2P3 filter = an organic vapour filter and a high efficiency particle filter.

A: organic vapour filter.

2: medium capacity.

P3: high efficiency particulate filter.

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Breathing apparatus (BA)

Breathing apparatus (BA) relies upon a supply of fresh air, either:

XX From an air hose whose outlet is in an uncontaminated atmosphere and relies on the
operator’s lung power to draw in the fresh air.

XX From an airline using a compressor to provide a powered supply of filtered breathable air.

XX Self-contained breathing apparatus, which may be open or closed circuit.

Open circuit systems supply air to the wearer from a cylinder either worn on a back pack or
from a remote location.

Closed circuit systems remove excess carbon dioxide from exhaled air, which is then re-breathed
by the wearer. This type of apparatus is generally only used for emergency self-rescue purposes.

Fresh air hose BA Constant flow airline BA Self-contained BA


with a hood

Figure 3.16: Breathing apparatus types

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Start

Eliminate risks
if practicable

Justify RPE use

YES Is oxygen deficiency


possible?

Only consider BA NO Review as required

Identify materials
and risk band

Decide
dustiness/volatility

Decide on level of
protection required

Consider work-related
factors

Consider individual
wearer factors

Select RPE

Train those involved

Set up maintenance
system

Issue and use RPE

Supervise use of RPE

Figure 3.17: Key elements of successful RPE management

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Suitability / selection of RPE

Suitability of RPE

RPE is considered suitable if it is adequate and is matched to the wearer, the task and the
working environment, so that the wearer can work with minimum impediment and without
additional risks due to the protective equipment.

RPE is considered adequate if it can provide a level of protection required to reduce the
exposure to comply with the law.

RPE should only be selected and used after a justification has been made in the risk assessment
required by law. It can be used in the following situations:

XX Where an inhalation exposure risk remains after other reasonable controls have been put
in place, i.e. residual risk.

XX Short-term or infrequent exposures where other controls at source are not reasonably
practicable.

XX While putting in place other control measures (interim measures).

XX Emergency escape for safe exit from an area where hazardous substances may be
released suddenly in the event of control systems failures, such as a chlorine tank.

XX Emergency work or temporary failure of controls where other means of controls 
are not
reasonably practicable.

XX Where emergency rescue by trained personnel is necessary.

However, there may be also circumstances to issue RPE, not because other control measures
are inadequate on their own, but to provide additional protection if any of the control measures
fail to operate. In this type of situation, specialist support should be sought from, for example,
an occupational hygienist.

Selection of RPE

In order to decide on the suitability and selection the following factors must be taken into
account:

1 Chemical and toxicological related factors.

2 Task-related factors.

3 Worker-related factors.

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1 Chemical and toxicological related factors

The selection of RPE will need to consider all hazardous substance risk assessment factors:

XX Forms of substance, i.e. solids, liquids, gases.


XX Nature of the hazardous substance, for example: toxic, biological agent, dust in sufficient
quantities, etc.
XX Routes of entry into the body, i.e. inhalation, ingestion, absorption, direct entry.
XX Effects on the body, i.e. acute / chronic / synergistic, etc.

It will also require consideration of a number of factors, which are detailed below.

Oxygen deficiency

The air we breathe is made up primarily of nitrogen (78%) and oxygen (20.8%) and the amount
of oxygen is critical to life. The level of oxygen in air can be reduced by chemicals and can be
dangerous to life, for example:

XX When something is burning it uses up oxygen to burn.


XX Biological agents. using oxygen (for example) for metabolism and producing carbon dioxide.
XX Asphyxiants, for example: the presence of nitrogen as inert fire prevention/extinguishing
medium, when they dilute the air.

Any deviation in oxygen levels from 20.8% should be investigated and appropriate action taken.
Below 19% oxygen, the atmosphere is considered
to be oxygen-deficient.

Oxygen enrichment

In some processes and environments, such as oxy-gas welding, it is possible to have raised
levels of oxygen (more than 20.8%), which in turn lead to increased dangers of fire, explosion
or chemical reaction, making the work more hazardous.

Pure oxygen should never be used to ‘sweeten’ an atmosphere – for example, to rectify oxygen
deficiency or ‘kill off’ unwanted smells.

Confined spaces

A confined space is a substantially enclosed space, such as a chamber, tank, vat, silo, pit,
trench, pipe, sewer, flue, well or small room, with limited access and inadequate air exchange.
A confined space may not necessarily be enclosed on all sides. This space can create a life-
threatening situation due to:

XX a sudden release of high concentrations of hazardous substances


XX an oxygen deficiency due to the build-up of asphyxiants
XX the simple act of breathing.

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2 Task-related factors

Work rate

Higher work rates are associated with increased breathing and sweating, which can affect the
performance of some types of RPE and will influence the selection. Increased breathing rate
can cause contaminants to leak in, and sweating can cause face pieces to slip and leak. Work
rate is classified as:

XX Light: sedentary working.

XX Medium: sustained hand and arm work or brisk walking.

XX Heavy: heavy manual work.

Wear time

Tight-fitting masks become uncomfortable to wear for long periods, such as greater than 1 hour.
Because of this, wearers may be tempted to loosen or remove RPE. Tight-fitting masks with
fan-assisted or compressed air-supplied RPE, and loose-fitting face-pieces will help minimise
fatigue and discomfort.

Classify wear time as: 


Less than 1 hour – wear time up to 1 hour

More than 1 hour – wear time greater than 1 hour.

Abnormal temperature or humidity

In hot and humid conditions, wearing RPE increases heat stress, sweating and discomfort. Using
fan-assisted or compressed air-supplied BA would help to minimise the problems. In conditions
of extreme cold, air flow associated with fan-assisted or compressed air-supplied BA can cause
chilling effects.

Proprietary cooling and / or heating devices are available from RPE manufacturers, however,
proprietary heating / cooling devices using compressed air (vortex tubes) can place severe
demand on the quantity of compressed air from supply systems.

Power tools used

If powered tools and BA you are connected to the same air supply, it is essential to confirm that
the compressor can supply enough air for both at the same time.

It is also important to ensure that air jets from power tools (pneumatic or electric) do not
impact on RPE valves located in masks. If this happens, the protection provided by the RPE can
be greatly reduced.

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Clarity of vision

If a worker needs to see fine details when wearing RPE, types which include face protection
(full-face masks, visors, hoods) may not be ideal because they can be prone to scratching, misting
and surface contamination. In these cases, consider half-mask RPE, provide adequate lighting,
or choose designs which resist scratching and internal misting. Fan-assisted or compressed air
RPE are more resistant to misting. Some types include ‘tear-off’ consumable visors.

Clarity of communication

All RPE affects a worker’s ability to communicate. If the work requires clear and precise
communication, RPE incorporating proprietary communication devices should be used (ranging
from simple speech diaphragms to complex radio intercom systems), or other suitable forms
of communication.

Mobility

Where mobility at different heights or over large areas is necessary to perform the work,
certain types of RPE may cause safety hazards, such as those with trailing hoses which can
drag, snag or be a trip hazard. If you can’t avoid using trailing hoses, provide hose-support
gantries or safe systems of work.

Congested work area

If work in a congested area cannot be avoided, less bulky or restrictive RPE should be chosen,
such as smaller, lighter RPE, and without trailing hoses.

Potentially explosive atmosphere

If working in potentially explosive atmospheres, including oxygen-enriched (levels above


20.8%), intrinsically safe, light-alloy free and antistatic RPE may be required.

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3 Worker-related factors

Any items worn on the head for fashion, cosmetic or religious reasons can restrict the choice of
RPE – for example: incompatibility with facemask head harnesses. If they cannot be eliminated,
a loose-fitting hood worn over the accessory may be acceptable, provided it gives the required
level of protection.

Facial hair

Any beard, stubble, thick sideburns, long hair or moustache in the region where a facemask
is intended to seal to the face will cause leakage. If
this facial hair cannot be eliminated,
you should consider the use of loose-fitting face-pieces, which do not rely on a tight seal
in this region.

Facial markings

Deep cuts or scars, wrinkles, moles, warts, etc. can affect the seal of masks to the face. If these
are present in the face seal area, consider the use of loose-fitting face-pieces.

Spectacles or contact lenses worn

Spectacles with side arms are incompatible with full-face masks because they break the face
seal. RPE manufacturers can supply special frames, which fit inside their masks. Spectacles may
also interfere with the fit of half-masks, contact lenses may be preferable.

Careful consideration and additional training is needed for contact lens or spectacle wearers
and those using full-face RPE (masks, hoods, etc.):

XX If the lenses are dislodged, the wearer may remove the RPE to replace them while still in
the hazardous area, leading to exposure.

XX A dislodged lens may jam in one of the RPE valves, leading to loss of protection.

XX Contact lens wearers may be more susceptible to discomfort from the drying effects of
air flows.

Eye, head, hearing or facial protection may be required

Different forms of head-worn PPE can potentially interfere to prevent one or more of the
components from working correctly, such as goggles and half-masks, mask harnesses and
safety helmets). Where possible, choose equipment where the different forms of protection
required are integrally combined, such as eye, face, head and respiratory protection provided
by a fan-assisted helmet respirator.

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Relevant medical conditions

These include claustrophobia, heart disease, hearing defects, asthma and other respiratory
illness. Also relevant are day-to-day coughs, colds and skin conditions. Pregnancy also falls
under this heading.

The following examples of poor RPE selection are given by the UK’s Health and Safety
Executive (HSE):

Task RPE selected HSE comments

Handling grain, Nuisance dust NDMs are designed to catch large


wood dust mask (NDM) particles, not those reaching your
lungs. They are not ‘CE’-marked and
are not RPE. They should not be used
for compliance with law. Most of the
dust will go through the NDM and the
worker may end up with respiratory
sensitisation.

Work with organic NDM or NDMs are designed to catch large


solvent – based particle filters particles, not those reaching your lungs.
products for example: (marked P1, They are not ‘CE’-marked and are not
painting, decanting, P2 and P3) RPE. Particle filters do not trap organic
degreasing, glass solvent vapours. For many applications
re-enforced plastics Type A filters are suitable. Always seek
manufacture, printing manufacturers’ advice before choosing
works, etc. a filter.

Entering confined Respirators Respirators will not provide protection


spaces for example: against oxygen deficiency, and other
sewers or tanks, ship toxic substances may be present in
hold where rusting lethal concentrations. Use suitable BA.
iron or residual organic
matter is present.

Table 3.4: Examples of poor selection of RPE

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Assigned protection factor (APF)

The APF is the level of respiratory protection that can realistically be expected to be achieved
in the workplace by 95% of adequately trained and supervised wearers using a properly
functioning and correctly fitted respiratory protective device.

It is calculated, under test conditions by dividing the level of airborne contamination by the
level that would be breathed in (i.e. after the RPE has done its job). If there were 50mg/m3 of
contaminant in the air and 5mg/m3 got passed the RPE the APF would be 50/5 = 10.

The APFs for specific types of RPE are detailed in BS EN 529: 2005. A filtering half mask (Class FF
P1) has an APF of 4, whereas a self-contained open circuit compressed air breathing apparatus
with positive pressure demand has an APF of 2000.

The minimum protection required (MPR) from specific RPE can be calculated by measuring
the workplace concentration outside the facepiece of the RPE and dividing it by the maximum
allowable concentration inside the facepiece of the RPE (i.e. the WEL).

MPR = workplace concentration of contaminant outside RPE facepiece


maximum allowable concentration inside the RPE facepiece (WEL)

To ensure an appropriate level of protection the APF of the selected equipment should be
higher than the calculated MPR. The higher the APF the safer the wearer, assuming the RPE fits
well and is performing effectively.

WATCH. LISTEN. DO

Would you like to see more about how calculations for


minimum protection required (MPR) work? Calculating MPR
shows you a video of how to calculate the answer to an exam
question about MPR and APF. You can even have a go at
completing the calculations yourself.

© Astutis Ltd Element IB3: Hazardous chemicals – engineering controls and personal protective equipment
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EXAM QUESTIONS

An airborne contaminant has an Occupational Exposure Limit (OEL) of 10ppm,


8-hour time-weighted average (TWA). Engineering controls have been introduced but
the airborne concentration of the contaminant in a workshop has been measured at
180ppm, 8-hour TWA.

The occupational hygienist has selected a piece of respiratory protective equipment


(RPE) with an assigned protection factor (APF) of 20, which is to be worn temporarily by
all employees in the contaminated area.

Using the data above outline how the hygienist could have calculated the APF AND
whether the hygienist has made an appropriate selection. (4 marks)

Remember that you can have a go at answering these questions


online AND the answers expected by the examiners will also be
revealed!

© Astutis Ltd Element IB3: Hazardous chemicals – engineering controls and personal protective equipment
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Table 3.5 and 3.6 give required protection factors for respirators and BA.

Respirator Abbreviation Protection factor required

Efficiency of particle filter P1 4

P2 10

P3 40

Half mask respirator FFP1 4

FFP2 10

FFP3 20

Face mask FMP1 4

FMP2 10

FMP3 20

Powered respirator with mask TM1 10


(fan assisted)
TM2 20

TM3 40

Powered respirator with hood TH1 10


(fan assisted)
TH2 20

TH3 40

Table 3.5: Protection factors for respirators

BA Abbreviation Protection factor required

Constant flow airline BA with mask LD1 20

LD2 20

LD3 20

Constant flow airline BA with hood LDH1 10

LDH2 20

LDH3 40

Constant flow airline BA with full-face mask - 100

Constant flow airline BA suit - 200

Positive demand full-face mask SCBA 2000

Table 3.6: Protection factors for BA

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It should be noted that RPE may not provide the level of protection stated by the manufacturers.
This may be because:

XX Poor air flow or a reduction in battery power.

XX The fitting of incorrect cartridges or a failure to replace them before saturation.

XX Equipment incorrectly fitted or incompatible with other personal protective equipment


being worn.

XX The presence of other contaminants resulting in a decrease in saturation time.

XX Inadequate training in its use and particularly in the care that should be taken in
its removal.

XX Poor maintenance and inadequate storage resulting in the face piece being left exposed .

XX Damage occurring during use and inadequate monitoring and supervision to ensure the
equipment was always used when required.

XX The equipment might not have been manufactured to the appropriate standards.

EXAM QUESTIONS

When respiratory protective equipment is in use, it may not provide the level of
protection stated by the manufacturer.

Outline the possible reasons for this. (10 marks)

Remember that you can have a go at answering these questions


online AND the answers expected by the examiners will also be
revealed!

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RPE selector tool from the UK’s HSE

The decision to use PPE, including RPE, should be justified in a risk assessment. If you employ
five or more employees the risk assessment should be recorded.

In the UK the Health and Safety Executive (HSE) and the Scottish Centre for Healthy Working
Lives, have designed a step-by-step process for selecting RPE called the ‘RPE Selector’. It is
a generic approach and has been specifically designed to help small and medium-sized
enterprises. Following this approach is not compulsory, and alternative approaches can be
used to comply with the law.

Step 1

This section addresses the basic details about the company and the work environment. The
boxes on work details should describe the type of work being carried out. The work duration
and the work frequency should detail for how long and how often the work occurs.

Step 2

The control measures box should list the measures that are currently in place and in use for
complying with the law, such as:

XX Totally enclosed process and handling systems.

XX Local exhaust ventilation (LEV).

XX Partial enclosure with LEV.

XX General ventilation.

XX Bunds to limit the spread if leak occurs.

Step 3

This step determines the health hazard group of the substance/preparation used during the
work described in Step 1, and determines what level of protection is needed from RPE.

A copy of the safety data sheet(s) (SDS) for the relevant substances/preparations will be needed
to properly complete this step.

Step 4

This step should be completed for every RPE wearer. These factors affect the selection of RPE
for individual wearers and are dependent upon the work carried out and the wearer.

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STEP 1
Company Department

Date of assessment Section

Performed by Location

Work details Work duration

Work frequency

STEP 2
Control measures Reason for using RPE
Residual risk
Short duration work
Emergency escape
Interim measure
Emergency work / rescue
Confined space working
Unsure No Yes
Confined space? Comply with Confined Spaces
Risk of oxygen deficiency?
Regulations. Use only
Substance release?
breathing apparatus with PF
of 40, unless a higher PF is
Seek specialist
indicated in STEP 3
advice Go to STEP 3

STEP 3
Substance Risk phrase HHG Amount Dust/Vol PF

Highest PF required

STEP 4
Task related factors
Work rate Heavy, Medium, Light Clarity of vision critical
Wear time > 1hr, <1hr Clarity of communication critical
Abnormal temperature or humidity Congested work area
Power tools used, list below Potentially explosive area
Mobility critical

User’s name
Wearer related factors
Headgear (turban etc) Spectacles or contact lenses worn
Facial hair Eye, head or facial protection
Facial markings Medical condition, seek medical advice

Select RPE using this information and PART 2, or


show this form to your supplier/specialist advisor. RPE selected BA type:
Involve the wearer and provide a choice of RPE. Respirator type: Filter:

STEP 5 Fit test tight fitting RPE, and implement Signature of assessor:
RPE use in the workplace

Figure 3.18: RPE Selector Tool from the UK’s HSE

Face fit testing

Once the correct RPE has been chosen, it is important to ensure that it fits each individual
correctly. The performance of a tight fitting facepiece (i.e. full-face mask, a half-face mask, or
a filtering facepiece) relies heavily on the goodness of fit of the facepiece to the wearer’s face.
An inadequate fit will significantly reduce the protection provided to the wearer.

Fit testing is required to ensure that selected RPE can provide adequate protection for
the individual wearer. It is checks that a tight fitting facepiece matches the person’s facial
features and seals adequately to the wearer’s face. It is also a good tool for screening out
incompatible RPE.

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Facepiece fit testing could also be used as a training tool to show the consequences to
performance of poor fitting and misuse.

There are two basic types of RPE fit testing – qualitative and quantitative.

Qualitative fit testing: is a simple pass/fail test based


on the wearer’s subjective assessment of the leakage,
via the face seal region, of a test agent. If the wearer
can detect the test agent (either a bitter or sweet
tasting aerosol, or an odourous compound) the fit
test is failed.

Quantitative fit testing: provides a numerical measure


of the fit that is called a fit factor. These tests give an
objective measure of face fit. They require specialised
equipment and are more complicated to carry out.

Figure 3.19: Qualitative fit test: taste

Fit test reports should be available for all employees who wear RPE incorporating tight fitting
face pieces. The records should be retained by the employer and kept available for inspection
on request.

© Astutis Ltd Element IB3: Hazardous chemicals – engineering controls and personal protective equipment
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Storage and maintenance of RPE

Storage

Clean and safe storage facilities must be provided for all RPE. Also, people wearing RPE should
have comfort, tea, meal and other breaks in safety.

While most PPE will be provided on a personal basis, some items may be used by a number of
people. There should be arrangements for cleaning and disinfecting the PPE so there are no
health risks to the next person using it.

Maintenance

All RPE should be checked for correct functioning before each use.

Maintenance is a requirement for all RPE, except for single use RPE, and should be carried out
by properly trained personnel. An effective maintenance system includes the following:

XX Examination: checking for faults, damage, wear and tear, dirt, etc.

XX Testing: to ensure PPE is operating as intended.

XX Cleaning: including disinfection if appropriate.

XX Repair.

XX Replacement.

Records of examination and testing should be kept for five years.

Thorough maintenance, examination and tests should be carried out at least once a month.
However, if the RPE is used only occasionally, an examination and test should be made before
use and in any event the interval should not exceed three months.

Only spare parts from the original manufacturer should be used during maintenance and repair
of damaged RPE.

The responsibility for carrying out maintenance together with the details of the procedures to
be followed and their frequency should be put down in writing. Where appropriate, records
of tests and examinations should also be kept. The maintenance programme will vary with
the type of equipment and how it is used. For example, BA will require a regular planned
preventative maintenance programme which will include examination, testing and overhaul,
and record keeping. However, abrasion resistant gloves may only require periodic inspection by
the user. Manufacturers’ maintenance schedules and instructions should be followed.

© Astutis Ltd Element IB3: Hazardous chemicals – engineering controls and personal protective equipment
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PPE will have a useable ‘shelf life’. When it exceeds its shelf life, or is so badly damaged that
repair is not possible or too costly, then it needs to be replaced. In certain circumstances it may
be appropriate to provide a supply of disposable PPE, for example, single-­use coveralls.

Disposal

Contaminated RPE or components or any of the materials used to clean or disinfect the RPE
may need to be considered as hazardous waste. This will depend upon the specific substances,
such as lead, and the amounts generated. In some cases specific legislation may apply.

Examples of misuse of RPE

Wearer compatibility

XX Tight-fitting face-pieces and facial


hair.
XX Lack of fit test pass.

Compatibility with other PPE

XX Clash with goggles / spectacles.

XX Sidearm spectacles interfere with Figure 3.20: Ordinary side-arm spectacles worn
with a full-face mask, disturbing the face seal
seal.

Maintenance and cleaning Training / supervision failure

XX Sharing of dirty equipment. XX Nose bridge not formed.

XX Dirt preventing valves working. XX Put on upside down.

XX Perished valves / components. XX Not all straps used.

XX Broken / worn straps or drawstrings. XX Straps loosened or not tightened.

XX Deformed / missing components. XX Lack of flow checks.

XX Seals and O-rings missing. XX Hose connections not secure.

XX Incorrect assembly, such as an XX Air supply inadequate / poor quality.


inverted visor.
XX Filters incorrect / out of date / missing.

XX DIY modifications.

XX Battery inadequately charged.

© Astutis Ltd Element IB3: Hazardous chemicals – engineering controls and personal protective equipment
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WEB LINKS

Respiratory protective equipment (RPE) webpages from the UK's HSE


www.hse.gov.uk/respiratory-protective-equipment/index.htm

RPE Selector Tool from the UK's HSE and the Scottish Centre for Healthy Working Lives
www.healthyworkinglives.com/rpe-selector

Respiratory protection webpages from the US Occupational Safety and Health


Administration (OSHA)
www.osha.gov/SLTC/respiratoryprotection/index.html

EXAM QUESTIONS

An airborne contaminant has an Occupational Exposure Limit (OEL) of 10ppm, 8-hour


time-weighted average (TWA). Engineering controls have been introduced but the
airborne concentration of the contaminant in a workshop has been measured at
180ppm, 8-hour TWA.

The occupational hygienist has selected a piece of respiratory protective equipment


(RPE) with an assigned protection factor (APF) of 20, which is to be worn temporarily by
all employees in the contaminated area.

Outline other factors that should be taken into account when selecting appropriate RPE.
(6 marks)

Remember that you can have a go at answering these questions


online AND the answers expected by the examiners will also be
revealed!

© Astutis Ltd Element IB3: Hazardous chemicals – engineering controls and personal protective equipment
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Skin and eye protection

Skin protection

Some substances can pass through the skin and cause diseases in other parts of the body.
Other substances can cause ‘local effects’, which are limited to the skin itself. Dealing with local
effects first, there are four main groups of substances that can cause skin problems, mostly at
the site of skin contact:

XX Corrosive substances that can lead to burns.

XX Irritant substances that can lead to irritant


contact dermatitis.

XX Sensitising substances that can lead to allergic


contact dermatitis.
Figure 3.21: Irritant contact
XX Substances that cause other diseases, such as dermatitis
skin cancer.

Skin exposure can occur by several pathways:

XX Immersion: the skin is submerged into a liquid or powder.

XX Splashes: from decanting or mixing of liquids and powders.

XX Deposition: when droplets, dusts, fumes or aerosols contact the skin, either as part of a
work activity or incidental to it, such as emission from a nearby process.

XX Contact with contaminated surfaces: this can happen in a variety of ways, such as:

• directly handling a contaminated work-piece

• contact with contaminated work surfaces

• residues on hands transferred to the eyes, nose and mouth

• residues on hands transferred to tools, paperwork and food

• removing contaminated PPE incorrectly.

© Astutis Ltd Element IB3: Hazardous chemicals – engineering controls and personal protective equipment
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Choosing and using protective gloves

Skin contact at work mostly occurs on the hands and forearms. The gloves you choose should
be ‘suitable’, i.e. they should match the work, the wearer and the work environment. There are
several factors to consider:

XX The chemical resistance to the corrosive solution.

XX The chemical breakthrough time.

XX The type and duration of contact.

XX The level of dexterity and sensitivity required for the task.

XX The length of the glove to afford adequate protection, such as a glove or gauntlet.

XX The durability of the gloves.

XX The need to ensure that a suitable range of sizes is available for the various users.

XX Any employee allergies to the glove material or any other skin problems.

Glove manufacturers produce charts to show how well their gloves perform against a range
of single substances/chemicals, however, the performance of glove materials can vary slightly
from manufacturer to manufacturer. These charts usually use three key terms: breakthrough
time, permeation rate and degradation, taken from BS EN 374-3:2003 Protective gloves against
chemicals and micro-organisms.

Breakthrough time

The time a chemical takes to work through (permeate) the glove material and reach the inside
is the breakthrough time. The substances pass through the material without going through
pinholes or pores or other visible openings. This is the maximum time that a glove remains
effective. A high breakthrough time is most effective to minimise exposure.

Type of glove Acetone HCl NaOH Toluene Xylene

Butyl >8 hr >8 hr >8 hr 20 min 65 min

Neo-prene 12 min >8 hr >8 hr 21 min 30 min

Natural rubber 7 min 211 min >8 hr Not Tested Not Tested

Nitrile rubber NR NR NR 20 min 65 min

PVC NR 5 hr Not Tested NR NR

Table 3.7: Breakthrough times for gloves and specific substances

© Astutis Ltd Element IB3: Hazardous chemicals – engineering controls and personal protective equipment
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Permeation rate

Once breakthrough has occurred, the permeation rate is the amount of substance/water, etc.
that then moves through. The higher the rate the more of the chemical will get through the
glove. A low permeation rate is most effective to minimise exposure.

Measured breakthrough time Permeation performance level

> 10 1 Low

> 30 2

> 60 3

> 120 4

> 240 5

> 480 6 High

Table 3.8: Permeation levels for gloves

Degradation

Degradation is damage of the glove material. It may get harder, softer or may swell. It will crack
or tear more easily. Degradation indicates the deterioration of the glove material on contact
with a named substance. An excellent or good degradation rating is most effective to minimise
exposure.

No protective gloves can give 100% protection against exposure to hazardous substances.

As a rule protection levels when worn at work can be reduced by up to 75% compared to the
laboratory test conditions. This is because the workplace is often more complex, exposing the
gloves, for example, to more than one substance.

© Astutis Ltd Element IB3: Hazardous chemicals – engineering controls and personal protective equipment
56
Table 3.9 gives examples of suitable gloves with a range of chemicals.

Glove Weak Oils Aromatic Chlorinated Aliphatic Strong Strong PCBs


material acids/ solvents hydrocarbons solvents acids alkalis
alkalis

Butyl 
Natural
rubber   
Neo-
preneTM  
Nitrile
rubber 
PVC 
VitonTM    
Table 3.9: Glove materials for chemical hazards

Skin creams

Pre-work creams are often known as ‘barrier creams’


but this can give workers a false sense of security.
They do not a form a barrier in the same way that
protective gloves do.

Skin creams are designed to help maintain a stable and


adequately hydrated barrier layer so the skin remains
in good condition and retains its protective role.

Pre-work creams are designed for application at the start of work, after breaks, etc.

After work creams help to restore the natural oils and moisture in the skin, reduced by chemicals
or wet work, etc.

© Astutis Ltd Element IB3: Hazardous chemicals – engineering controls and personal protective equipment
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WEB LINKS

Skin at work webpages from the UK's Health and Safety Executive (HSE)
www.hse.gov.uk/skin/index.htm

Occupational skin disease and dermal exposure – policy and practice overview from
the European Agency for Safety and Health at Work (EU-OSHA)
osha.europa.eu/en/publications/reports/TE7007049ENC_skin_diseases

BS EN 374-3:2003 Protective gloves against chemicals and micro-organisms.


shop.bsigroup.com/ProductDetail/?pid=000000000030203728

WATCH. LISTEN

Go online to watch a video about how you should Protect your


skin. You can also read a range of case studies about workers
who have been affected because they didn't protect their skin.

EXAM QUESTIONS

Workers in a chemical plant are provided with gloves to protect against the possible
effects of the chemicals. In recent months, there has been an increase in the number of
hand and lower arm skin complaints amongst these workers.

Outline possible reasons for this increase in skin complaints. (10 marks)

Remember that you can have a go at answering these questions


online AND the answers expected by the examiners will also be
revealed!

© Astutis Ltd Element IB3: Hazardous chemicals – engineering controls and personal protective equipment
58
Eye / face protection

Eye and face protection can be specified to protect against chemical and biological hazards
including:

XX Chemical splashes.

XX Fine dusts and powders.

XX Fumes, vapours and gases.

XX Biological agents/viruses.

When choosing safety eye wear the following should be considered:

The nature of the hazard: the chemical risk, etc., the form of the chemical (spray, gas, dust,
etc.), other hazards in the activity which may cause a risk to the eyes and/or face.

The risk factors: the risk of acid splashing the face as well as eyes, for example.

Intended use: eye wear suitable for chemical and micro-biological


hazards are labelled ‘other use’ (as opposed to welding, lasers). BS
EN 166:2002 Personal Eye Protection. Specifications defines the
performance standards, including basic use, impact resistance, liquids,
coarse dust, gases and fine dusts.
Eye protection
must be worn
Type of lens: such as clear, tinted, filter, mesh, and the material and in this area

the shape, such as safety glasses, goggles or visors.

Ocular performance: classifies performance against a range of criteria including abrasion


resistance and resistance to fogging and misting.

Comfort and fit: one size non-adjustable spectacles are common and cheap but provide
comfort and fit to all wearers. Spectacles should have adjustable side arms and tilting frames
to provide good comfort and fit.

Compatibility with other PPE: side arms of spectacles and headbands of goggles maybe
incompatible with full-face masks and ear protectors, etc.

© Astutis Ltd Element IB3: Hazardous chemicals – engineering controls and personal protective equipment
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Suitable styles of eye protection are shown in Table 3.10:

Type Picture Description

Safety Will afford some protection against


spectacles chemical splashes, protection is improved
with side shields.

Eye shields may be worn over corrective


spectacles.

Safety Cup type (with separate eye coverings) or


goggles box type (with a single covering).

Provide a higher level of protection than


spectacles – as the eyes are enclosed the
afford protection against fine dusts, gases
and vapours, and biological agents.

May be less comfortable and prone to


misting.

Face Protects the whole face from impact


shields or chemical splashes but offers little
protection against dust and fume.

Table 3.10: Eye / face protection

© Astutis Ltd Element IB3: Hazardous chemicals – engineering controls and personal protective equipment
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WEB LINKS

Eye and face protection eTool from the US Occupational Safety and Health
Administration (OSHA)
www.osha.gov/SLTC/etools/eyeandface/index.html

BS EN 166:2002 Personal Eye Protection. Specifications


shop.bsigroup.com/en/ProductDetail/?pid=000000000030036277

EXAM QUESTIONS

A slightly corrosive solution is used as a treatment in part of a manufacturing process.


The solution is applied by hand brushing. Other methods of application have been
found to be impractical.

Outline the factors that should be considered in the selection of personal protective
equipment (PPE) to protect skin and eyes. (10 marks)

Remember that you can have a go at answering these questions


online AND the answers expected by the examiners will also be
revealed!

© Astutis Ltd Element IB3: Hazardous chemicals – engineering controls and personal protective equipment
61
Body protection

There are several different types of body protection, for example:

XX overalls

XX aprons

XX appropriate footwear.

Different materials will protect against different chemical and physical hazards. It is important
to check with the clothing manufacturer to make sure that the material selected will provide
protection from the specific chemical exposure.

Materials for chemical protective clothing include:

XX Paper-like fiber: disposable suits made of this material provide protection against dust
and splashes.

XX Treated wool and cotton: protective clothing made from treated wool and cotton adapt
well to changing workplace temperatures and is comfortable as well as fire resistant.
Treated cotton and wool clothing protects against dust.

XX Rubber, neoprene, and plastics: protective clothing made from these materials protects
against certain acids and other chemicals.

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General considerations when choosing PPE

After considering the specific requirements of skin and eye protection, the following general
issues should be considered:

XX Consultation and user trials.

XX Comfort of the equipment.

XX That everything purchased meets the relevant product safety standard.

Hazard Title EN Standard

RPE Full-face masks BS EN 136: 1998

Particle filters BS EN 143: 2000

Gloves 'Wet work' (waterproof) BS EN 374-2: 2003

Substances/chemicals BS EN 374-3: 2003

Mechanical hazards BS EN 388: 2003

Thermal hazards BS EN 407: 2004

Eye protection Specification for personal eye protection BS EN 166: 2002

Body protection Protective clothing against liquid chemicals BS EN 466-1:1995

Table 3.11: Examples of EN standards for PPE

© Astutis Ltd Element IB3: Hazardous chemicals – engineering controls and personal protective equipment
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General training for PPE

The following training should be given to users of PPE:

XX The health risks of the chemical in use.

XX The type of personal protection to be used and the reason for its use.

XX The methods to be used for putting on and taking off the equipment without causing
contamination including decontaminating or discarding gloves after use.

XX The methods of examining the equipment for damage or degradation, particularly gloves,
and for reporting defects and obtaining replacements.

XX How to store the equipment correctly.

XX How to carry out self-examination of the skin and the action to be taken if problems were
to occur.

This is the basic training requirement. However, there may also be other specific training
depending upon the PPE used, for example: breathing apparatus.

EXAM QUESTIONS

A slightly corrosive solution is used as a treatment in part of a manufacturing process.


The solution is applied by hand brushing. Other methods of application have been
found to be impractical.

Identify the content of a training programme that will assist workers to use the PPE
correctly. (5 marks)

Remember that you can have a go at answering these questions


online AND the answers expected by the examiners will also be
revealed!

© Astutis Ltd Element IB3: Hazardous chemicals – engineering controls and personal protective equipment
64
Practical measures to ensure correct use of PPE

Other than training, there are practical measures that can be taken to increase the correct use
of PPE. These include:

XX Management leading by example.

XX Employees being involved in the selection of the equipment.

XX Ensuring the availability of a range of sizes in gloves and fully adjustable face shields.

XX Ensuring employees were required to sign for their equipment and maintaining records
of issue.

XX Issuing the equipment on a personal basis and providing adequate storage facilities.

XX Using propaganda, signs and posters and incentive schemes.

XX Monitoring compliance in the use of the equipment with a recognised code of discipline
for non-use.

XX Monitoring the effectiveness of the equipment issued and replacing it with an alternative
type if problems were encountered.

EXAM QUESTIONS

A slightly corrosive solution is used as a treatment in part of a manufacturing process.


The solution is applied by hand brushing. Other methods of application have been
found to be impractical.

Excluding training outline a range of practical measures that can be taken to


encourage the use of the PPE and maintain its effectiveness. (5 marks)

Remember that you can have a go at answering these questions


online AND the answers expected by the examiners will also be
revealed!

© Astutis Ltd Element IB3: Hazardous chemicals – engineering controls and personal protective equipment
65
IB3 References

ACGIH (2004) Industrial Ventilation: A Manual of Recommended Practice, 25th Edition, ACGIH,
Cincinatti, Ohio.

BSI (2003) Protective gloves against chemicals and micro-organisms. Terminology and
performance requirements – BS EN 374-1:2003, BSI, London.

HSE (2011) Controlling Airborne Contaminants at Work, a Guide to Local Exhaust Ventilation
(LEV) HSG258, HSE Books, London.

HSE (2009) Managing Skin Exposure Risks at Work, HSG262. HSG258, HSE Books, London.

HSE (2008) Clearing the Air, A simple Guide to buying and Using Exhaust Ventilation (LEV),
INDG408, HSE Books, London.

HSE (2005) Control of substances hazardous to health (Fifth edition) – The Control of Substances
Hazardous to Health Regulations 2002 (as amended), Approved Code of Practice and guidance
– L5, HSE Books, London.

HSE (2005) Respiratory protective equipment at work: A practical guide HSG53, HSE
Books, London.

ILO (1993) Safety in the use of chemicals at work: An ILO code of practice, International Labour
Office, Geneva.

ILO (2001) Ambient Factors in the Workplace, an ILO Code of Practice, International Labour
Office, Geneva.

© Astutis Ltd Element IB3: Hazardous chemicals – engineering controls and personal protective equipment
66
© Astutis Ltd.

All rights reserved.

No part of this study material may be stored in a retrieval system,


reproduced or transmitted in any form, or by any electronic,
photographic or other means without the express written permission
of Astutis Ltd.

Applications for written permission to reproduce any part of this


study material should be sent to Astutis Ltd., 6 Charnwood Court,
Parc Nantgarw, Cardiff, CF15 7QZ.

Information sourced from the Health and Safety Executive and


Government Departments has been reproduced and / or adapted
under the terms of the open government license for public sector
information version 2.0, as presented by the National Archives at:

www.nationalarchives.gov.uk/doc/open-government-licence/
version/2/

Information obtained from other sources has been properly


acknowledged and referenced.

Whilst every effort has been made to ensure the currency and
accuracy of the information contained within Astutis Ltd. bears
no liability for any omissions or errors; or any concepts and
interpretations advanced by the authors.

Version 1.1 2015

© Astutis Ltd Element IB3: Hazardous chemicals – engineering controls and personal protective equipment
67

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