Professional Documents
Culture Documents
3.1 Ventilation 4
Fit 28
Training 29
Skin protection 54
Body protection 62
References 66
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3.0 3.0 Learning outcomes
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 ventilation:
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.
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
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Local exhaust ventilation (LEV)
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 Cleans the air (if necessary) and gets rid of the contaminants safely.
XX The source is large and LEV is impossible to apply over the entire source.
XX The source emits relatively small amounts of contaminant (which is not toxic).
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
XX An inlet, for example: a hood or enclosure, to collect and contain the contaminant close
to its source.
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
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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.
Paint-spraying
booth
Less effective
Hood face
( b ) Receiving hood
Hood
face Hood face
( a ) Enclosing hood
( c ) Capturing 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 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
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Ducting
Designers should take the following points into account with regard to ductwork:
XX Have a sufficiently high air velocity to keep particles suspended in the air stream, while
low enough to keep noise levels acceptable.
XX Have the minimum number of bends and junctions to minimise the flow resistance.
XX Provide drainage points at any low points in an LEV system for aerosols, mists, or
substances that may condense or support combustion.
Taking into account the physical conditions and chemical nature of the contaminants, ducting
materials should:
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 at low points
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.
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)
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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
XX Impingement: medium-size
Dust collection
particles meet the fibres within bag or hopper
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.
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Cyclones Clean air
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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
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
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 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 Centrifugal are the most commonly used fans for LEV systems.
XX Turbo exhauster.
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 Flammability or combustibility.
XX Space limitations.
Propeller fans
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
Centrifugal fans
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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:
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Factors reducing 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.
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.
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 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.
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
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:
Cameras, fibre-optic camera and boroscopes can be used for internal LEV examinations.
Inlet
Face or capture velocity. See Figure Face of booth divided into Meter placed in
imaginary rectangles midpoint of each rectangle
3.10.
Ducts
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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
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.
XX an outside contractor
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.
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.
XX The name and address of the employer responsible for the LEV.
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 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
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
(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)
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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.
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 suitable PPE
XX maintained 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.
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.
The risk assessment will indicate the type of protection required from:
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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 Young workers.
XX Pregnant workers.
XX Workers wearing, for example, contact lenses or prescription glasses, which may be
affected by the PPE.
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
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.
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.
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.
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
Personal protective equipment (PPE) advice from the UK’s Health and Safety Executive
(HSE)
www.hse.gov.uk/toolbox/ppe.htm
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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.
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.
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.
Simple Power
Fresh air hose Powered airline Self-
filtering assisted
BA BA contained BA
respirators respirators
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.
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Respirators
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.
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.
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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.
Therefore an A2P3 filter = an organic vapour filter and a high efficiency particle filter.
2: medium capacity.
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Breathing apparatus (BA)
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.
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.
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Start
Eliminate risks
if practicable
Identify materials
and risk band
Decide
dustiness/volatility
Decide on level of
protection required
Consider work-related
factors
Consider individual
wearer factors
Select RPE
Set up maintenance
system
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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 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.
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:
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:
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:
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:
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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:
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.
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.
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.
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.
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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 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.
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):
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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).
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
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EXAM QUESTIONS
Using the data above outline how the hygienist could have calculated the APF AND
whether the hygienist has made an appropriate selection. (4 marks)
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Table 3.5 and 3.6 give required protection factors for respirators and BA.
P2 10
P3 40
FFP2 10
FFP3 20
FMP2 10
FMP3 20
TM3 40
TH3 40
LD2 20
LD3 20
LDH2 20
LDH3 40
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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 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.
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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 General ventilation.
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
Performed by Location
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
STEP 5 Fit test tight fitting RPE, and implement Signature of assessor:
RPE use in the workplace
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.
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.
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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 Repair.
XX Replacement.
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.
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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.
Wearer compatibility
XX Sidearm spectacles interfere with Figure 3.20: Ordinary side-arm spectacles worn
with a full-face mask, disturbing the face seal
seal.
XX DIY modifications.
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WEB LINKS
RPE Selector Tool from the UK's HSE and the Scottish Centre for Healthy Working Lives
www.healthyworkinglives.com/rpe-selector
EXAM QUESTIONS
Outline other factors that should be taken into account when selecting appropriate RPE.
(6 marks)
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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 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:
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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 length of the glove to afford adequate protection, such as a glove or gauntlet.
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.
Natural rubber 7 min 211 min >8 hr Not Tested Not Tested
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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.
> 10 1 Low
> 30 2
> 60 3
> 120 4
> 240 5
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.
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Table 3.9 gives examples of suitable gloves with a range of chemicals.
Butyl
Natural
rubber
Neo-
preneTM
Nitrile
rubber
PVC
VitonTM
Table 3.9: Glove materials for chemical hazards
Skin creams
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.
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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
WATCH. LISTEN
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)
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Eye / face protection
Eye and face protection can be specified to protect against chemical and biological hazards
including:
XX Chemical splashes.
XX Biological agents/viruses.
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.
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.
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Suitable styles of eye protection are shown in Table 3.10:
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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
EXAM QUESTIONS
Outline the factors that should be considered in the selection of personal protective
equipment (PPE) to protect skin and eyes. (10 marks)
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Body protection
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.
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:
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General training for PPE
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 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
Identify the content of a training programme that will assist workers to use the PPE
correctly. (5 marks)
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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 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 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
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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.
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© Astutis Ltd.
www.nationalarchives.gov.uk/doc/open-government-licence/
version/2/
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.
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