1. Respiratory Protection— The Case of the Wrong Respirator
P O W E R P O I N T ® T R A I N I N G
Background for the Trainer:
This case and its training message primarily have to do with respiratory protection. Therefore, it is most appropriate for workers who are required to wear respirators or voluntarily wear respirators in your workplace. This session is probably not appropriate for workers who are not exposed to respiratory hazards.
This training session presents a case study of an actual accident, which was inspected and documented by the Occupational Safety & Health Administration (OSHA). The case presented in this training session is:
Accident:
Report ID:
Inspection:
You may choose to present this training information in a lecture format, or make the training presentation interactive by engaging your class in discussions that will help them identify facts of the case, potential causes of the accident, and future accident prevention measures. In either case, students will benefit by learning from a real-life scenario.
Before beginning your training session, print and make copies of the one-page Case Study Student Handout, which is provided on the disc. The Case Study Student Handout can be used as a worksheet during the training session, or as a take-away reminder once the training session is complete.
Also, print and make copies of the Case Study Quiz, which is provided on the disc as a fully customizable Word document. The students can take the quiz at the end of the training session in order to help reinforce the information presented. Note that the same quiz is included at the end of this PowerPoint presentation as actual slides to review in class.
Consider taking pictures of employees wearing respirators in your workplace. You can add these pictures to the presentation by inserting them into existing slides or creating new slides.
Make sure that the trainees understand the message as you go along. Periodically ask questions to test their understanding.
Speaker’s Notes:
Welcome everyone. Today we will conduct a case study of an actual accident, which was investigated by the Occupational Safety & Health Administration (OSHA). This is an actual, tragic, workplace accident that had real-life implications for the worker, the worker’s family, co-workers, and the employer. The Case Study may be disturbing and may even involve a fatality.
The purpose of this training session is to teach and reinforce the importance of respiratory protection in our workplace in order to prevent tragic accidents. In particular it deals with how to select the appropriate respirator to protect against the specific respiratory hazard. The intention is to learn from the accident and to take steps to prevent a similar accident from occurring at our facility.
Respiratory Protection— The Case of the Wrong Respirator

2. Respiratory Hazards Inhalation of airborne dusts or particulates
Inhalation of vapors or fumes
Lack of adequate oxygen
Identify hazardous materials
Measure exposure
Background for the Trainer:
Use this slide as an opportunity to discuss potential respiratory hazards in your workplace.
Speaker’s Notes:
Respiratory hazards include the inhalation of airborne dusts or particulates. These dusts might be from grinding, cutting, sanding, or even welding operations. Other dusts are from grains, wood chips, or other solid granular materials.
Another common respiratory hazard is the exposure to vapors or fumes. Using solvents, spraying with aerosol cans, painting operations, bulk loading or unloading of materials, and handling drums of materials are just a few examples of jobs that could result in inhalation of vapors or fumes.
A respiratory hazard that is not as common, though very dangerous, is exposure to a lack of oxygen. This hazard is usually associated with jobs that require confined space entry in which there may not be sufficient oxygen for a worker to enter without supplied-air respiratory protection.
Assess your job or workplace for potential respiratory hazards such as exposure to dusts, vapors, or a lack of oxygen. Then identify the hazardous materials that may be the source of the respiratory hazard. Review work processes to determine where hazardous exposures occur, as well as the magnitude of the exposure(s).
Exposure monitoring may be required to measure the magnitude of worker exposure to hazardous substances.

3. Take a Look at the Facts
Employee applying 1,1,1-trichloroethane primer inside 5' x 5' planter boxes
Wearing half-face cartridge respirator
Employee becomes unconscious
Background for the Trainer:
Training Option: Pass out the Case Study Student Handout. You may have the students read the accident description to themselves before discussing it in the class, or you may use the bullet points on the slide and the Speaker’s Notes below to describe the accident.
Speaker’s Notes:
Employee #1 is applying primer that is pure 1,1,1-trichloroethane to the inside concrete walls of 5' x 5' planter boxes with varying depths of 8 feet, 12 ft, and 16 ft. Two of each size, six in all, are to be primed. These planter boxes should have been considered confined spaces.
The employee is wearing a cartridge-type (air-purifying) half-face respirator rather than a supplied-air type of respirator that is required for 1,1,1-trichloroethane.
The employee is overcome and becomes unconscious from the toxic vapors.

4. Take a Look at the Facts (cont.)
Second employee attempts rescue without respirator
Also falls unconscious
Speaker’s Notes:
A second employee attempts to rescue the first employee.
The second employee is not wearing any respirator. He also was overcome and fell unconscious.
© Business & Legal Reports, Inc. 0908

5. Take a Look at the Facts (cont.)
Fire Department rescues both employees
1,1,1-trichloroethane measured 80,000 ppm
Speaker’s Notes:
The Fire Department rescues both employees.
Measurements indicate at least 80,000 parts per million (ppm) of 1,1,1-trichloroethane vapors at the bottom of the 16-ft planter box that employee #1 had entered. The immediately dangerous to life and health (IDLH) level for 1,1,1-trichloroethane is 1,000 ppm.

6. What Do You Think Went Wrong?
Did the employee know the primer contained 1,1,1-trichloroethane?
Did the employee know the vapor levels were up to 80,000 ppm?
Was the right type of respirator selected?
Was respiratory protection training provided?
Was there a written Respiratory Protection Plan?
Background for the Trainer:
Use the questions on this slide to elicit discussion.
Training options: After reviewing this slide and the accident description, give the class 5–10 minutes to discuss the accident description in small groups; or, ask the students to try to determine some of the facts, potential causes, and possible prevention measures. In either case, use the Case Study Student Handout as a way to encourage discussion as you go through this presentation.
Speaker’s Notes:
Let’s take a few minutes and, using the Case Study Student Handout, work in groups to try to determine the facts of the accident, potential causes of the accident, and possible prevention measures. Then we will review the Case Study together in class.
Consider some of the questions on this slide when discussing the Case Study in your groups.

7. Let’s Review the Causes
High concentration of 1,1,1-trichloroethane vapors
Wrong type of respirator selected
Lack of a hazard assessment
Lack of employee training
Lack of a Respiratory Protection Plan
Background for the Trainer:
Try to get the trainees to put themselves in the place of the person in the Case Study. What would they have done in this case? Point out how a near miss can turn into a catastrophe in an emergency. In this case, the worker was not wearing the right type of respirator to protect him from the high concentration of 1,1,1-trichloroethane vapors.
Speaker’s Notes:
The high concentration of 1,1,1-trichloroethane vapors was the primary cause of the injury. These employees could have died from exposure to 80,000 ppm of 1,1,1-trichloroethane. They were very fortunate.
The employee selected the wrong type of respirator for the high concentration of 1,1,1-trichloroethane. When selecting respiratory protection, you need to know the magnitude of exposure. Some states use a system of assigned protection factors to help select the appropriate respirator. For example, a half-face air-purifying respirator may only protect up to 10 times the permissible exposure level (PEL), while a full-face supplied-air respirator may protect up to 1,000 times the PEL. When the level of exposure is unknown, assume IDLH (immediately dangerous to life and health) conditions and wear an SCBA (self-contained breathing apparatus) or a supplied-air system with a 5-minute emergency escape bottle.
The employee did not assess the potential respiratory hazards before starting the job. The employee may have used this primer before in an open space with plenty of ventilation, so the vapor concentration would not have been that dangerous. The employee probably did not consider the fact that he was working in a small, confined space with little ventilation, as well as the fact that 1,1,1-trichloroethane vapors are heavier than air and would stay at the bottom of the small space. Monitoring should have been done to determine employee exposure levels.
Although the investigation report does not tell us, we can probably assume that the employee was not properly trained in how to assess the respiratory hazards of the job or how to select the appropriate respirator.
The investigation report does not tell us for sure, but we can also probably assume that the employer did not have a written Respiratory Protection Plan, because a properly written program would include respiratory protection practices for each job or task.
Can you think of any other causes that may have contributed to this accident?

8. Respiratory Protection
Filtering face piece
Air-purifying respirator
Different types of cartridges
Air-supplied respirator
Self-contained breathing apparatus (SCBA)
NIOSH-approved
Speaker’s Notes:
A filtering face piece, commonly called a dust mask, is worn when employees are exposed to dusts. When exposed to low levels of dust, often just referred to as nuisance dust, employees may choose to voluntarily wear a dust mask. If employees are exposed to high levels of dust that exceed PELs, as determined by monitoring, the employees will be required to wear a filtering face piece. Filtering face pieces are for dusts only and do not protect against vapors or fumes.
An air-purifying respirator utilizes a cartridge or filter to purify the air that is breathed by workers. Both full-face and half-face air-purifying respirators are used to protect employees exposed to vapors or fumes. If monitoring shows that employees are not overexposed, employees may choose to voluntarily wear a respirator. If monitoring shows employees are overexposed, employees are required to wear the air-purifying respirator. Air-purifying respirators cannot be used for exposure to high concentrations of materials or in atmospheres that do not have adequate oxygen.
Air-purifying respirators have a number of different types of cartridges to choose from. There is not one cartridge that will filter out all types of contaminants, so it is important to select the appropriate cartridge for the specific contaminant. Additionally, employers need to determine how long it may take for the material to “break through” the cartridge and therefore determine how often the employees need to change cartridges.
Air-supplied respirators are used for exposures to high concentrations of materials or in atmospheres that do not have adequate oxygen.
Self-contained breathing apparatuses (SCBAs) are used in conditions that are considered IDLH, such as an emergency response to material spills.
All respirators and filtering face pieces used in the workplace must be certified by the National Institute for Occupational Safety and Health (NIOSH).

9. Wear and Care of Respirators
Obtain medical approval
Perform a fit test
Inspect before each use
Seal check
Clean regularly
Store properly
Background for the Trainer:
Bring copies of your company’s written Respiratory Protection Program.
Show pictures of your employees wearing respirators, being fit-tested, inspecting and cleaning their respirators, doing seal checks, and storing their respirators properly.
Speaker’s Notes:
Workers who wear respirators must be medically approved. Your company’s Respiratory Protection Program should have more details concerning medical approval.
Workers who wear respirators must be fit-tested annually. Fit-testing involves the use of smoke or saccharin to determine if the respirator properly seals to the worker’s face.
Employees must inspect the respirator before each use and look at things such as the seal, head straps, valves, cartridges, etc., for signs of cracking, wear, or other damage. Any damaged parts should be discarded and replaced.
Each time a worker puts on his or her respirator, they should conduct a seal check to make sure the respirator properly seals to their face. The positive seal check involves exhaling while blocking the exhalation valve to see if air escapes from the face seal of the respirator. The negative seal check involves covering the inhalation valves while inhaling—the respirator should stay caved in. If not, the seal leaks and allows air into the respirator.
Respirators must be cleaned regularly. Daily cleaning might involve using an alcohol wipe. A thorough cleaning involves taking the respirator apart and cleaning it in soap and water. Then allow the parts to air dry.
Respirators must be stored properly to protect them from dust and other contaminants. Put the respirator in a sealed plastic bag and store it so that it retains its natural shape.

10. Don’t Let It Happen to You
Assess the respiratory hazards
Know the level of exposure
Select the appropriate respirator
Make sure your respirator fits
Properly clean and store your respirator
Speaker’s Notes:
Let’s take a look at what we can do to prevent a similar incident from happening at our facility.
Assess the respiratory hazards of your job. Look for exposure to dusts, vapors, or lack of oxygen.
Know the level of exposure. Monitor the exposure. If you are below OSHA’s PEL, you may still wear a respirator voluntarily. If your exposure is over OSHA’s PEL, you are required to wear a respirator.
Select the appropriate respirator. Air-purifying cartridge respirators are acceptable for exposure to low concentrations. Air-supplied respirators must be used when exposed to high concentrations.
Make sure your respirator fits you properly. If the seal to your face leaks, you will not be protected from the hazard. Make sure you are properly fit-tested at least annually. Also, do a seal check before each use of the respirator.
Keep your respirator in good condition by cleaning it regularly and storing it so that it is protected from contaminants and maintains its natural shape.
Are there any questions?
Thanks for your attention.

11. Quiz 1. Name two primary categories of respiratory hazards.
2. True or False? A filtering face piece will protect you from dusts and solvent fumes.
3. Respirators must be certified by what organization?
4. True or False? Before wearing a respirator, you must be medically approved.
5. What type of respirator must be worn in environments that lack oxygen?
Background for the Trainer:
Remind employees that the quiz is used to encourage further discussion and to help you, the trainer, be sure that everyone understands what was discussed.
Print copies of the quiz for participants to take on their own, or go over the questions as part of the training session.
© Business & Legal Reports, Inc. 0908

12. Quiz (cont.)
6. Each time you put a respirator on, what should you check?
7. In what environments are air-purifying respirators safe to use?
8. When inspecting your respirator, what do you look for?

13. Quiz Answers 1. Q. Name two primary categories of respiratory hazards.
A. Dusts, vapors, lack of oxygen.
2. Q. True or False? A filtering face piece will protect you from dusts and solvent fumes.
A. False. Filtering face pieces do not protect you from solvent fumes.
3. Q. Respirators must be certified by what organization? A. NIOSH.
© Business & Legal Reports, Inc. 0908

14. Quiz Answers (cont.)
4. Q. True or False? Before wearing a respirator, you must be medically approved.
A. True.
5. Q. What type of respirator must be worn in environments that lack oxygen?
A. Air-supplied respirators.
6. Q. Each time you put a respirator on, what should you check?
A. Check the seal.
© Business & Legal Reports, Inc. 0908

15. Quiz Answers (cont.)
7. Q. In what environments are air-purifying respirators safe to use?
A. Low concentration of exposure.
8. Q. When inspecting your respirator, what do you look for?
A. Cracks, wear, cuts, other damage.