Authored By: Blanchard Refining Company LLC Doc No.

: RSW-000025-GB
Tray Hart Galveston Bay Refinery Rev No: 6
Doc Custodian:
Safety Supervisor Refinery Safe Work Procedure
Approved By: PPE-5 Respiratory Protection
Eric Kaysen
Date Approved: 2/23/2021 Next Review Date: 5/31/2026 Effective Date: 5/27/2021

TABLE OF CONTENTS

1.0 Purpose 2
2.0 Scope 2
3.0 Procedure 2
3.1 General Requirements 2
3.2 Respirator Selection and Use 2
3.2.14 Air Purifying Respirators (APR’s) 3
3.2.15 Supplied-Air Respirators 3
3.2.16 Special Use Respirators 4
3.2.17 Emergency Use Respirators 4
3.3 Bottle Watch 4
3.4 Cascade System Cylinders 4
3.5 Immediately Dangerous to Life and Health (IDLH) Work 5
3.5.1 Back-up Person 5
3.6 Back-up requirements for working in fresh air 5
3.7 Fresh Air Job Planning 5
3.8 Respirator Care 6
3.8.1 Inspection 6
3.8.2 Respirator Repair and Maintenance 7
3.8.3 Cleaning and Disinfecting 7
3.8.4 Storage 7
3.9 Breathing Air Quality 7
3.10 Breathing Air Compressors 8
3.11 Training and Fit Testing 10
3.12 Medical Evaluation 10
3.13 Recordkeeping 11
3.14 Respiratory Protection Program Evaluation 11
3.15 Contractors 12
4.0 Definitions 12
5.0 References 13
6.0 Attachments 13
7.0 Revision History 14
Attachment A: Galveston Bay Refinery HESS Department Approved Respiratory Protection 15
Attachment B: GBR Respirator Selection Matrix (1 of 3) 16
Attachment B: GBR Respirator Selection Matrix (2 of 3) 17
Attachment B: GBR Respirator Selection Matrix (3 of 3) 18
Attachment C: Air Purifying Respirator Cartridge Change-out Schedule 19
Attachment D: Galveston Bay Refinery Monthly Respiratory Protection Inspection Checklist 20
Attachment E: Respirator Cleaning Requirements 21
Attachment F: Typical Air Cylinder System for Field Use of Supplied Air Respiratory Protective Equipment
22
Attachment G: Contractors Required To Have a Respirator Program 23
Attachment H: Fresh Air Work Checklist 24
Attachment I: Breathing Air Compressor/Breather Box Checklist 25
Attachment J: Breathing Air Calculation Guideline 26
Attachment K: GBR Facial Hair Requirements 27
Attachment L: Information for Employees Using Respirators When Not Required Under the Standard 28
Attachment M: Picture of Breathing Air Line Tag 29

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Blanchard Refining Company LLC Galveston Bay Refinery
Title: PPE-5 Respiratory Protection Doc Number: RSW-000025-GB Rev No: 6

1.0 Purpose
This plan presents the standard operating procedures covering the selection and use of respiratory
protection in work areas or job assignments where it is not feasible to control exposures to airborne
contaminants or oxygen-deficient atmospheres to acceptable levels through the use of engineering
controls and work practices. It is intended to address the requirements of the OSHA Respiratory
Protection Standard 29 CFR 1910.134 and relevant company guidelines.
2.0 Scope
This practice applies to all MPC personnel and contractors who routinely use a respirator for work inside
the refinery or may encounter a need for respiratory protection during the course of their work or who may
need respiratory protection during the course of an emergency response. This standard does not apply to
third party ambulatory members who are responding to an onsite emergency.
3.0 Procedure
3.1 General Requirements
Respiratory protection will be used only after feasible engineering or administrative controls have
been considered and cannot reduce potential exposures to acceptable levels.
3.1.1 To wear a respirator, an employee must be medically qualified, fit tested annually, and be
clean-shaven.
3.1.2 All respiratory protection equipment intended for MPC personnel must be approved by
the Safety Department. See Attachment A for Safety Department approved respiratory
protective equipment.
3.1.3 The designated Program Administrator is the Safety Supervisor.
3.2 Respirator Selection and Use
3.2.1 Respirators will be selected based on potential hazards that the worker may be exposed
to during work activities.
3.2.2 A respirator selection matrix (Attachment B) has been developed to assist in the selection
of appropriate respiratory protection within the Galveston Bay Refinery (GBR).
3.2.3 Manufacturer's guidelines on respirator fitting and usage shall be followed. Only
respirators that have been certified by the National Institute for Occupational Safety and
Health (NIOSH) are approved for use.
3.2.4 Regardless of the respirator selected, each time a respirator is donned, the employee
must inspect it for any defects and perform a positive and negative pressure test (fit
check) to ensure a proper seal has been achieved.
3.2.5 Employees trained in respirator selection and their limitations will identify the proper
respirator by referring to Attachment B.
3.2.6 Factors that must be considered when selecting a respirator include chemical state,
physical form, duration of wear, expected physical work, temperature, humidity and a
reasonable estimate of exposure based on actual, historical, or objective data.
3.2.7 Engineering Controls must always be considered prior to selecting respiratory protection.
3.2.8 When hazards are encountered that are not covered by Attachment B or if an employee
has any question regarding respirator selection for a specific application, they should
contact the Safety Department.
3.2.9 GBR employees are required to use respirators in accordance with manufacturer
instructions and training provided.
3.2.10 Only personnel who have received a fit-test wallet card that indicates which respirator(s)

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Title: PPE-5 Respiratory Protection Doc Number: RSW-000025-GB Rev No: 6

they have been quantitatively fit tested on are approved to wear a respirator. Personnel
are only approved to wear the respirators they have been quantitatively fit tested on.
3.2.11 Personal protective equipment (e.g. safety glasses) shall not be worn in a manner that
will interfere with the respirator face piece-to-face seal. Employees who need
prescription safety glasses and use supplied air respirators will be provided clear
prescription lenses, frames (excluding temple pieces) and a lens holder assembly.
Contact lenses may be worn instead of the assembly kit.
3.2.12 The purpose of any respirator is to isolate the wearer from the surrounding contaminated
atmosphere by providing a leak-tight seal between the mask and the face.
3.2.13 Facial hair of MPC employees and contractors included in the Respiratory Protection
Program shall not exceed the limits depicted in Attachment K. Even a few days’ growth
of stubble in the clean-shaven area is not permitted. Facial piercings that interfere with
the facepiece-to-face seal are also prohibited.
3.2.14 Air Purifying Respirators (APR’s)
APR’s are respirators that purify inhaled air through the use of a
filter/cartridge. Atmospheric monitoring or knowledge of the process
conditions will be utilized to determine the contaminant(s), approximate
concentrations, and appropriate cartridges/filters to be used. APRs will be
cleaned and stored appropriately after each use. APR cartridges will be
discarded when use has exceeded time limits outlined in Attachment C, or if
warning properties are noted (chemical odor breakthrough or limited airflow
due to particulate buildup.)
APR's are not appropriate in areas that are Immediately Dangerous to Life
and Health (IDLH) or in areas with less than 19.5% oxygen. These situations
require the use of supplied-air respirators.
3.2.15 Supplied-Air Respirators
See section 3.5 for IDLH Work requirements and section 3.6 for Fresh Air
Work Planning requirements.
Within the Refinery, supplied-air respirators are either the self- contained
breathing apparatus (SCBA) or the airline respirator. Both shall be the
"positive-pressure" type with an emergency egress air supply and a low-
pressure alarm, with the exception of specialty respirator (i.e. abrasive
blasting).
Airline hoses from air supplying cylinders or breathing air compressors shall
be NIOSH certified and protected from damage, including cutting, kinking,
crushing, or burning.
Hose couplings shall be protected against inadvertent disconnection.
Modification or repair of the airline hoses is prohibited. Trailing airline hoses
will be arranged to minimize tripping hazards and to permit escape. No
individual hose line shall exceed 300 feet in length from point of attachment
or three (3) couplings (whichever is less) downstream of low pressure
regulator. If upstream hose used, it must be engineered and approved by
manufacturer for use with breathing air.
Completed respirator assembly and their components must be NIOSH
approved and be include on the NIOSH approval label.
When air is supplied from cylinders, the air cylinder regulator shall be set to
maintain a normal operating pressure not to exceed 125 psi. All air cylinders
will be set up per manufacturer specifications. Do not mix hose type or

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Title: PPE-5 Respiratory Protection Doc Number: RSW-000025-GB Rev No: 6

coupler assemblies. See Attachment F for an example setup. Any variance

from this system must be approved by the Safety Department.
The Breathing Airline hose connection at the source or the point of
connection leading to the source must be adequately tagged with a “Do Not
Disconnect” tag with the user’s full name and company included on the tag.
(Only 1 tag needed per user)
Note: Tagging requirement does not apply to MPC personnel in emergency
situations or when a bottle watch is not required per section 3.3.1.
3.2.16 Special Use Respirators
Special use respirators are respirators that are designed and used for
specific work activities or for specific conditions (i.e. welding, sandblasting,
etc.) Special use respirators shall only be used for their associated work
activity.
3.2.17 Emergency Use Respirators
Emergency egress bottles provide short duration (~ 5 minutes) breathing air
and are designed for escaping emergency situations. Examples within the
Refinery include the, 5 & 10 minutes Survivair or Scott Escape Breathing
Apparatus.
Emergency egress air supplies shall only be used in emergencies and their
valves never opened unless an emergency situation exists.
Chemical, Biological, Radiological, and Nuclear (CBRN) escape respirators
are in designated buildings as required by RSP-1314 PSM/RMP Building and
Tent Siting standard. These respirators shall only be used for escape during
emergencies.
3.3 Bottle Watch
3.3.1 For use of airline respirators, a bottle watch must be designated. In some cases, the
bottle watch may be the user or monitored at a remote location; such cases may include
SRU loading, Alky Truck unloading, Air Carts, or an airline bottle attached to mobile
equipment.
3.3.2 The bottle watch must be trained in the requirements of airline respirator systems.
3.3.3 The bottle watch must monitor compressed breathing air cylinders at ALL times while
equipment is in use.
3.3.4 Maximum 2 people will be allowed for each cylinder.
3.3.5 The bottle watch must maintain communication with workers at ALL times (e.g. hand
signals, voice, radio, etc.).
3.3.6 The system must be equipped with an alarm that will sound when the cylinder pressure
reaches 500 psi.
3.3.7 Employees must be alerted by the bottle watch at 600 psi and egress when cylinders
reach 500 psi.
3.3.8 Ensure Attachment H or Attachment I is completed and maintained at the jobsite.
3.3.9 The bottle watch is responsible for ensuring breathing airline hose connections are
adequately tagged with “Do Not Disconnect” tag with user’s full name and company at
the source or the point of connection leading to the source, and for disconnecting
breathing airline hoses.
3.4 Cascade System Cylinders

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3.4.1 When starting with a full cascade system, it is recommended to open appropriate number
of cylinders needed for the job. Use Attachment J to calculate breathing air required for
the job.
3.4.2 “Hot Switching” (i.e., changing out cylinders, opening and closing cylinders while
personnel are using the cascade system) is not allowed.
3.4.3 Bottle Watch shall notify wearers of low levels, prior to sounding of low-pressure alarm.
3.4.4 The switch of empty bottles to full bottles may be done when wearers have exited the
potentially hazardous area. The bottle watch shall remove the cylinder tag stub labeled
"IN USE" portion of the empty cylinder, to identify that the cylinder is empty. The full
cylinder tag shall read "IN USE".
3.4.5 The cascade to a full cylinder should be indicated by checking pressure gauge on
systems regulator, pressure reading is dependent upon cylinder size and type.
3.5 Immediately Dangerous to Life and Health (IDLH) Work
3.5.1 Back-up Person
When using airline respirators in an IDLH situation, a backup person who is
trained and equipped to provide emergency rescue (i.e. retrieval equipment
or equivalent means) must be in the ready state outside the barricade.
The backup person must don the respirator and be ready to hook up as
needed.
If the work is in an IDLH environment, the backup person must be on a
separate breathing air system as the person doing fresh air job.
3.6 Back-up requirements for working in fresh air
All permitted maintenance invasive activities utilize the RAM score. If the
RAM scored is based on IDLH/potential IDLH; a back-up is needed.
When Operations is searching for a leak, or unknown hazard, a back-up is
needed.
Operations performing work which can potentially create a hazardous
atmosphere and if there is no egress or egress is limited, a back-up is
needed.
The minimum ratio of backup personnel to workers is 1:3.
The backup person must don the respirator and be ready to hook up as
needed.
3.7 Fresh Air Job Planning
3.7.1 Provide adequate source of air. Calculate how much air you will need for the job by using
Attachment J.
3.7.2 Review access and egress.
3.7.3 Red “DO NOT ENTER” barricade tape and signs must be placed on all sides around
fresh air jobs, before the job begins. If fresh air work is performed from a platform, no one
is allowed to enter the area immediately above and below the grade where the work is
performed.
3.7.4 The Safe Work Permit and Job Safety Analysis shall address additional precautions such
as size of barricade, including barricade below and above grade if work on platform,
continuous or periodic gas testing extending the barricade, etc. This barricade may be
larger dependent on the Safe Work Permit and Job Safety Analysis.
3.7.5 Plan hose lay out and routing. Trailing airline hoses will be arranged to minimize tripping

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Title: PPE-5 Respiratory Protection Doc Number: RSW-000025-GB Rev No: 6

hazards and to allow escape. No individual hose line shall exceed 300 feet in length from
point of attachment or three (3) couplings (whichever is less).
3.7.6 A pre-use inspection of all breathing air components (including hoses) shall be completed
for all fresh air work. See Attachment H.
3.7.7 Any hose not in acceptable condition per Attachment H or within annual inspection shall
not be used and MPC owned hoses should be returned to Safety Repair.
3.7.8 Attachment H - Fresh Air Work Checklist must be completed by the Servicing Group
Representative and the MPC Maintenance Representative (if contract work) for all fresh
air work. The checklist will be attached to the SWP permit.
3.7.9 Employees must have face to face discussion with the Servicing Group Representative
before task starts.
3.7.10 When fresh air is used for routine operations task, precaution should be reflected in
Normal Operating Procedure (NOP).
3.7.11 For turnaround work, the breathing air service contractor will submit a written Safety
Execution Plan to the Safety Turnaround Coordinator on scope of work inclusive of
procedures to verify when safe to isolate breathing air.
3.8 Respirator Care
3.8.1 Inspection
All respirators shall be inspected by the user before and after each use
(unless disposed). Worn or deteriorated parts on MPC air supplied
respirators shall be noted and the respirator sent to the Safety Repair Shop.
Supplied-air respirators will be inspected monthly by the group controlling the
respirator. Unit or Area respirator inspections shall be conducted in
accordance to manufacturer's guidelines. Supplied-air respirator inspection
dates with findings shall be recorded during monthly inspections. These
monthly inspection records will be kept in a file maintained by the group
controlling the respirator. These records must be maintained for one year
and be retrievable on demand. See Attachment D for an example of an
inspection record.
Emergency Egress CBRN Respirator totes will be inspected monthly by the
safety equipment contractor via PRIDE. The respirator tote car seals shall be
intact and unbroken. If one is found to be damaged or removed, Safety
Repair (409-945-1530) at East/West Plant or DNOW (713-534-7773) at Bay
Plant will need to be contacted to replace any missing or opened respirators
with new respirators in kind.
If any defects are noted during the facility monthly inspection, the respirator
shall be removed from service and sent to the Safety Repair Shop for repair
and a replacement respirator shall be supplied. Damaged air-purifying
respirators shall be discarded and replaced with new air-purifying respirators.
Emergency use supplied-air respirators will be inspected by the Safety
Repair Shop after each use (exception: Fire Department will inspect their
own equipment). Escape Respirators will be disposed of after each use.
All supplied air units will be sent to the Safety Repair Shop at least every
year for a thorough inspection and cleaning. All associated regulators will be
returned to the manufacturer at the manufacturer recommended frequency
for a thorough inspection in accordance with their recommendations.
SCBA cylinders will be hydrostatically tested every three (3) years and
escape bottles will be tested every five (5) years.

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Blanchard Refining Company LLC Galveston Bay Refinery
Title: PPE-5 Respiratory Protection Doc Number: RSW-000025-GB Rev No: 6

The Safety Repair Shop will maintain records of respirator inspections,

regulator inspections, hydrostatic tests, and maintenance/repair records.
3.8.2 Respirator Repair and Maintenance
The Safety Repair Shop will be responsible for the repair and maintenance of
all supplied air respiratory equipment.
Repairs will be done only by qualified Safety Repair Shop
personnel.
A qualified person is one that is trained and certified by the
manufacturer to repair the respirator.
The air-purifying respirators at Galveston Bay Refinery shall be discarded if
any part is missing or defective.
3.8.3 Cleaning and Disinfecting
The air purifying respirator should be cleaned and disinfected by the
individual as often as necessary to ensure the respirator is maintained in a
clean condition. See Attachment E for guidance on respirator cleaning.
Supplied-air respirators shall be cleaned and disinfected as frequently as
necessary to ensure the respirator is maintained in a clean condition.
Face pieces used by multiple individuals must be cleaned and
disinfected after every use.
Supplied-air respirators will be cleaned and disinfected per
manufacturer’s recommendations. Refer to Attachment E for
guidance on cleaning/disinfecting respirators.
3.8.4 Storage
After inspection, cleaning, and necessary repair, respirators shall be stored
to protect against dust, sunlight, heat, extreme cold, excessive moisture, and
damaging chemicals.
Respirators will be packed or stored with the face piece and exhalation valve
resting in a position that does not damage or impair the elastomer face piece.
Respirators will NOT be stored in places such as lockers or tool boxes unless
they are in a sealed carrying case, bag, or carton.
SCBA, breathing air cylinders, regulators, airlines, etc. that are kept outdoors
shall be protected against dust, dirt, chemicals, insects and other conditions
that might render the equipment unsafe.
SCBA and other supplied-air respirators placed at stations and work areas
for emergency use shall be stored in compartments built for that purpose, be
quickly accessible at all times, and clearly marked.
Each operating unit will provide proper storage facilities for the respiratory
equipment normally used on the unit. The Safety Repair Shop will provide
proper storage facilities for respiratory equipment not normally stored on
operating units.
The Fire Department will be responsible for their own respiratory equipment.
3.9 Breathing Air Quality
3.9.1 Breathing air must be certified at a minimum to Grade D as described in
ANSI/Compressed Gas Association (CGA) Commodity Specification for Air (G-7-1-1989).
3.9.2 Breathing air cylinders will be charged with certified breathing air meeting requirements

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Title: PPE-5 Respiratory Protection Doc Number: RSW-000025-GB Rev No: 6

for “Grade D” air as defined by the CGA. Breathing air cylinders shall be clearly labeled
as such.
3.9.3 Breathing air manufactured by blending oxygen and nitrogen is forbidden to be used.
Only breathing air cylinders filled by compressing ambient air must be used.
3.9.4 Certificate of analysis must be obtained for every lot of cylinders documenting Grade D
quality breathing air. Safety Repair Shop personnel will maintain the certificate of analysis
for 5 years for bottles they fill.
3.9.5 When bottles are being filled by Safety Repair Shop, personnel will check the certificate
of analysis against the specifications for Grade D breathing air and check that the
certificate matches the lot number.
3.9.6 In cases where breathing air does not meet Grade D specifications and/or certificate
does not match the lot number, the following actions will be taken:
Tag cylinders with “Do Not Use” sign
Contact vendor/supplier immediately
3.9.7 Airline couplings (CGA approved for breathing air) will be incompatible with outlets for
other gas systems to prevent inadvertent servicing of airline respirators with non-
respirable gases or oxygen.
3.9.8 Use of “Plant Air” for breathing is prohibited.
3.10 Breathing Air Compressors
3.10.1 The Safety Repair Shop may fill MPC SCBA cylinders using an MPC owned compressor,
provided the compressor meets the following requirements:
Only breathing-air type compressors shall be used.
The breathing air supplied by the compressors must meet “Grade D”
requirement listed above.
Non-oil lubricated compressors for supplying air shall have alarms to indicate
high temperature and compressor failure.
Oil lubricated compressors for supplying air must be equipped with high
temperature and carbon monoxide alarms.
Breathing air compressors must have their air intakes placed in areas
providing clean air.
Airline couplings will be incompatible with outlets for other gas systems to
prevent inadvertent servicing of airline respirators with non-respirable gases
or oxygen.
Maintenance and repair of compressor shall be done in accordance of
manufacturer instruction.
3.10.2 In certain situations, compressors can be used to provide supplied air. In these
situations, the following minimum requirements must be met:
Air compressor breathing air systems must be set up, inspected and
maintained by an individual with adequate training and experience to ensure
the system is capable of delivering Grade D breathing air throughout its use
and that all requirements of the NIOSH certification are being met.
The compressor must be capable of delivering a sufficient volume of air per
minute to accommodate: (1) the maximum number of persons who will be
breathing from the system at any given time, (2) the length of airline being
used, (3) the use of vortex tubes for cooling, and (4) the specific type of

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respiratory equipment being used, as specified in the respirator’s

instructions.
The compressor must be located in an atmosphere suitable for breathing and
away from process sewers, sample taps, process vents, and exhaust from
internal combustion engines.
The area surrounding the compressor and high-pressure hoses must be
barricaded.
All air supply connections shall be secured to eliminate the possibility of the
connection parting.
All unattended valves supplying breathing air shall be secured to eliminate
the possibility of breathing air being inadvertently shut off.
The compressor’s fuel level must be adequate to ensure continuous
operation while in use or must be monitored during the work day.
An after-cooler shall be located immediately downstream of the compressor
to remove heat and water vapor from the air.
A properly inspected and maintained “Breather Box”, supplied by the
approved safety equipment supply contractor, must be connected
downstream of the compressor and upstream of the airlines and NIOSH-
approved supplied-air respirators.
Note: These breather boxes DO NOT remove carbon monoxide that can be
introduced into the inlet of the compressor or that can be produced by the
compressor due to overheating of the oil used in the compression chambers.
A functioning carbon monoxide alarm is the only line of defense against
carbon monoxide poisoning.
A tag containing the most recent date of sorbent bed
replacement and the signature of the person performing the
change shall be in the Breather Box.
The Breather Box must always be maintained in the upright
position during use and close enough so that the Carbon
Monoxide (CO) alarm can be heard by standby person
positioned near the breather box. In addition, remote warning
lights and alarm are available to connect to the Breather Box.
The use of the Breather Box must be in accordance with the
manufacturer’s instructions, including ensuring that:
The CO alarm has been tested and the monitor
turned on before each use.
The inlet pressure to the box does not exceed
the manufacturer’s specifications.
The regulator(s) on the breather box has been
adjusted to the pressure specified in the
respirator’s instructions given the length of hose
and cooling devices being used.
Air flow through the CO monitor has been
properly set after all workers and equipment are
connected.
In the event of a CO alarm, workers must immediately be
instructed to leave the work area and told to remove their

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respiratory protective equipment. Tampering with or disabling

the function of the CO monitor or alarm is prohibited.
Breather boxes are to be returned to the approved safety
equipment supply contractor for inspection and maintenance
every 30 days and sooner if breathing air quality is suspect.
Airline couplings will be incompatible with outlets for other gas
systems to prevent inadvertent servicing of airline respirators
with non-respirable gases or oxygen.
Breathing air compressors are not permitted for entry into
atmospheres considered Immediately Dangerous to Life or
Health (IDLH).
Attachment I - Breathing Air Compressor Checklist must be
completed by the Servicing Group Representative and the MPC
Maintenance Supervisor (if contract work) for all work using
breathing air compressor as air source. The checklist will be
attached to the SWP permit.
3.10.3 Breathing air systems (i.e. Cobra) will be inspected by the provider using their own
inspection documentation.
3.11 Training and Fit Testing
3.11.1 Each employee whose job may require respirator usage will be given initial
classroom/hands-on training and a detailed annual WBT training on proper use, care,
selection, inspection and limitations of respirators.
If work conditions change that render previous training obsolete, or if issues
arise that indicate retraining is necessary for safer respirator use, more
frequent training will be conducted.
Every respirator wearer will receive instructions and practice in how the
respirator will be worn, adjusted, and how to determine if it fits properly.
The training will include the use of airline respirator, escape respirator, SCBA
and half-mask air purifying respirator.
Training records will be retained by the Galveston Bay Refinery Learning and
Development Department for the duration of employment.
3.11.2 Employees that are required to wear respirators will be given annual quantitative fit
testing. Fit testing may be conducted more frequently if a respirator user has a change in
facial structure which would invalidate previous fit testing (e.g. dramatic loss of weight,
significant dental work, etc.) Fit testing records will be retained by the Galveston Bay
Refinery Medical Department for one year or until the next fit testing is conducted.
3.11.3 Fit testing is not required for use of CBRN escape respirators provided in designated
buildings as required by RSP-1314 PSM/RMP Building and Tent Siting standard.
3.11.4 Contractors must receive equivalent training and provide documentation upon request.
Contractor will maintain a list of qualified bottle watches.
3.12 Medical Evaluation
3.12.1 The Galveston Bay Refinery Medical and Safety Departments in consultation with
employee’s supervisor will determine which MPC job assignments require or may require
respiratory protection within the Refinery.
No one shall be assigned to a task requiring the use of respirators unless
they are medically “qualified” to use respiratory protective equipment. Each
employee included in the program will complete a medical questionnaire to

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be evaluated by the Galveston Bay Refinery Medical Department.

The Galveston Bay Refinery Medical Department shall make the decision as
to the fitness of the individual to wear a respirator and if an additional medical
examination is necessary.
The Galveston Bay Refinery Medical Department will issue a written
recommendation on the employee’s ability to wear a respirator. Re-
evaluation will be based on Medical, IH, Safety, or supervisor
recommendation, or if the employee reports signs or symptoms of difficulty
wearing a respirator.
3.12.2 Personnel on the Fire Department, regardless of position, will be in the respirator
program.
3.12.3 Personnel that go into a respirator required area must be in the respirator program.
3.12.4 Medical evaluation and inclusion in the respiratory protection program is not required for
use of CBRN escape respirators provided in designated buildings as required by RSP-
1314 PSM/RMP Building and Tent Siting standard.
3.12.5 Voluntary users of respirators in non-hazardous (non-required) situations must still meet
the medical qualification requirements outlined above. This does not include exclusive
nuisance dust (comfort) mask users that do not require fit tests.
3.13 Recordkeeping
3.13.1 The Safety Repair Shop will maintain records of their respirator inspections, regulator
inspections, hydrostatic tests, maintenance/repair records, and certificate of analysis.
Inspection records will be maintained for one year.
3.13.2 The Galveston Bay Refinery Medical Department will maintain respiratory protection
program medical records (i.e. medical questionnaires). Records will be maintained for
the duration of employment plus 30 years.
3.13.3 The HESS Department will maintain the fit testing records for one year or until the next fit
test is conducted.
3.13.4 Unit or area supervision will maintain unit/area monthly inspection records for a period of
one year.
3.13.5 The Galveston Bay Refinery’s Learning and Development Department will maintain all
respiratory protection related training records for the duration of employment.
3.14 Respiratory Protection Program Evaluation
3.14.1 Once every 3 years an evaluation to determine the continued effectiveness of this
respirator program will be conducted by the Safety Department. The evaluation will
include:
Assessment of workplace conditions to ensure that the approved respirators
are still adequate for the contaminant and concentrations encountered.
Evaluation of actual respirator usage; including:
Visual inspection of employees on the job to see that respirators
are worn properly and on the job(s) specified.
Examination of respirators in storage to check for proper
maintenance.
Solicitation of wearer comments.
3.14.2 Any deficiencies will be recorded, assessed, and corrected. Additionally, the Respiratory
Protection Policy will be modified if needed.

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3.15 Contractors
3.15.1 For a list of contractors by work type that are required to have a respirator program,
please reference Attachment G. Contractors whose work falls under the OSHA
Respiratory Protection Standard (29 CFR 1910.134) must:
Maintain a written program that meets or exceeds the requirements of this
practice and applicable standards.
Ensure employee compliance with their written program.
When requested, provide compliance documentation (i.e. fit test, medical
qualification, training records, etc.) to MPC.
Supply their personnel with respiratory protection equipment (unless
otherwise specified in the contract).
Compliance with the Facial Hair requirements of this practice.

4.0 Definitions
4.1 Supplied Air Respirator (SAR) – Respirators that provide a respirable atmosphere to the
wearer, independent of the ambient air. They are either an airline respirator or SCBA.
4.2 Airline (Hoseline) Respirator – Respirable air is supplied through a small diameter airline from a
compressor or compressed air cylinder(s). The airline is attached to the wearer by a belt and can
be detached rapidly in an emergency. A regulator is provided to govern the rate of airflow to the
wearer.
4.3 Self-Contained Breathing Apparatus (SCBA) – Supply of air, oxygen, or oxygen generating
material is carried by the wearer and is normally equipped with a full facepiece respirator.
4.4 Air-Purifying Respirator – Any respirator equipped with air-purifying cartridges to remove
gases, vapors, and particulate matter from the ambient air prior to its inhalation. Air-purifying
respirators must not be used in oxygen deficient atmospheres as they do not provide oxygen.
4.5 “Breather Box” – The system filters inlet air to provide respirator users Grade-D quality air. The
first stage filters bulk water and particulate, second stage coalescing filter eliminates atomized
oils, mists, and ultra-fine particulates, third stage removes some organic vapors and odors. Filter
change indicators are standard on all three stages. Filter efficiency is 99.99% @ 0.01 microns. It
is equipped with a built-in carbon monoxide (CO) monitor with an external alarm and light to
signal the worker of high CO content. Consult with HESS before using any breather box.
4.6 Ceiling Value – The ceiling value is a concentration that should never be exceed at any time
during the day. In the event that instantaneous monitoring is not feasible, then the ceiling value
shall be assessed as a 15-minute exposure.
4.7 Hazardous Atmosphere – Any atmosphere which is either oxygen deficient (< 19.5% O2) or
which contains toxic or disease-producing contaminants exceeding the legally established
permissible exposure limit (PEL) or, where applicable, the Threshold Limit Value (TLV).
4.8 Hot Switching - Opening and closing valves on manifold.
4.9 Immediately Dangerous to Life or Health (IDLH) – Any atmosphere that poses an immediate
hazard to life or produces immediate, irreversible, or debilitating effects on health (i.e. less than
19.5% oxygen, toxic atmosphere greater than listed IDLH value in Attachment B).
4.10 PEL – Permissible Exposure Limit as promulgated by OSHA. PEL’s are the average airborne
exposure to a substance in any 8-hour work shift of a 40-hour work week which shall not be
exceeded.
4.11 Demand and Pressure-Demand – With a demand respirator, air is delivered to the facepiece
only when the wearer inhales, thereby creating a slight negative pressure in the facepiece. With a
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pressure-demand respirator, air is delivered to the facepiece in a manner that maintains a

positive pressure in the facepiece at all times, even during inhalation.
4.12 Safety Repair Shop – MPC Galveston Bay Refinery safety equipment shop located at the
refinery main warehouse.
4.13 STEL – The short-term exposure limit is a 15-minute average exposure that an employee shall
not exceed at any time during a workday.
4.14 TLV – Threshold Limit Value as developed by the American Conference of Governmental
Industrial Hygienists. TLV’s are the average airborne exposure to a substance in any 8-hour
work shift of a 40-hour work week which shall not be exceeded.

5.0 References
5.1 29 CFR 1910.134, OSHA Respiratory Protection Standard
5.2 NIOSH Guide to Industrial Respiratory Protection, DHHS (NIOSH) Publication No. 87-116
5.3 ANSI Z88.2 - 1980, American National Standard Practices for Respiratory Protection
5.4 3M, Respirator Selection Guide
5.5 NIOSH, Pocket Guide to Chemical Hazards
5.6 ACGIH, Threshold Limit Values for Chemical Substances and Physical Agents - Biological
Exposure Indices

6.0 Attachments
6.1 Attachment A: TC Refinery HESS Department Approved Respiratory Protection
6.2 Attachment B: TCS Respirator Selection Matrix
6.3 Attachment C: Air Purifying Respirator Cartridge Change-out Schedule
6.4 Attachment D: Galveston Bay Refinery Monthly Respiratory Protection Inspection Checklist
6.5 Attachment E: Respirator Cleaning Requirements
6.6 Attachment F: Typical Air Cylinder System for Field Use of Supplied Air Respiratory Protective
Equipment
6.7 Attachment G: Contractors Included & Required To Have a Respirator Program
6.8 Attachment H: Fresh Air Work Checklist
6.9 Attachment I: Breathing Air Compressor Checklist
6.10 Attachment J: Breathing Air Calculation Guideline
6.11 Attachment L: Information for Employees Using Respirators When Not Required Under the
Standard
6.12 Attachment M: Picture of Breathing Air Line Tag

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Title: PPE-5 Respiratory Protection Doc Number: RSW-000025-GB Rev No: 6

7.0 Revision History

Revision Description of Change Written by Approved by Revision Effective

Number Date Date

Original issue. Consolidated procedure

that replaces GBR-HESS-PPE-05 and
0 RSW-0004-TC under MOC 51561 and S. P. Streacker D. C. Staats 8/8/2018 3/11/2019
adds full-face APR option for East/West
Plant under M201710914-001.

Adds Bay Plant Emergency Egress Mouth

1 Bit Respirator cabinet inspection under C. T. Hart V. J. Meeks 7/16/2019 7/16/2019
MOC 63299.

Adds new breathing airline hose tag and

2 clarifies requirements when disconnecting C. T. Hart V. J. Meeks 3/11/2020 3/20/2020
breathing airline hoses under MOC 71182.

Clarifies breathing air hose tag

3 C. T. Hart E. R. Kaysen 4/15/2020 5/21/2020
requirements.

Drops Mouthbit Escape and updates

monthly inspection requirements for
4 C. T. Hart E. R. Kaysen 12/23/2019 7/15/2020
emergency egress respirator storage
locations under MOC 65196.

Adds back-up requirements for working in

5 C. T. Hart E. R. Kaysen 1/4/2021 2/11/2021
fresh air under MOC 78886.

Updated to address applicability to third-

6 party ambulatory personnel under MOC C. T. Hart E. R. Kaysen 2/23/2021 5/27/2021
85443.

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Title: PPE-5 Respiratory Protection Doc Number: RSW-000025-GB Rev No: 6

Attachment A: Galveston Bay Refinery HESS Department Approved Respiratory Protection

Air Purifying
Respirator Brand Respirator Type Plant
3M – 6000 Series Half-Mask East/West Plant
North – 3000 Series Half-Mask East/West Plant
North RU6500 Series Full-face East/West Plant
MSA ComfortClassic Half-Mask Bay Plant
North 7700 Half-Mask Bay Plant
Scott AV-2000 Full-face Bay Plant
Air Supplied
Respirator Brand Respirator Type Plant
Survivair/Honeywell – Panther equipped with Classic,
Classic Modified with Welding Attachment, or 2020 SCBA East/West Plant
Plus Mask
Survivair/Honeywell – Panther Warbler High Pressure
SCBA East/West Plant Alky 3 Only
CBRN equipped with HUD and 2020 Plus Mask
Survivair/Honeywell – Panther Warbler High Pressure East/West Plant
SCBA
NSG equipped with HUD and 2020 Plus Mask Fire Department Only
Scott AV-2000 SCBA / Airline Bay Plant
Survivair/Honeywell Panther Hippack w/ 5-minute
SCBA / Airline East/West Plant
Escape
Specialty
Respirator Brand Respirator Type Plant
Survivair/Honeywell EBA 5 & 10 Minute Escape East/West Plant
Survivair/Honeywell Hippack 15 Minute with 2020 Plus
Escape East/West Plant Alky 3 Only
Mask
Scott Escape 5 & 10 Minute Escape Bay Plant
Honeywell ER2000CBRN CBRN Escape Hood Escape East/West and Bay Plant
Avon NH15 CBRN Escape Respirator Escape East/West and Bay Plant
Bullard-88 Type C Escape East/West and Bay Plant
3M Disposable Dust Mask N95 (See Attachment L) Dust Mask East/West and Bay Plant

This table only applies to MPC personnel.

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Attachment B: GBR Respirator Selection Matrix (1 of 3)

Contaminant Exposure level Respirator 1 Cartridge (color) 2 PEL/TLV 3, 6 STEL 4, 6 IDLH 5, 6 Notes
Acetonitrile Less than 20 ppm None Required - 20 ppm 500 ppm
20 – 200 ppm Half Mask OV (black or yellow)
201 – 500 ppm Full Face OV (black or yellow)
Greater than 500 ppm Supplied Air -
Ammonia Less than 25 ppm None Required - 25 ppm 35 ppm 300 ppm Half mask at 50 ppm or less
25 – 50 ppm Half Mask Ammonia (green) with appropriate eye protection
51 – 300 ppm Full Face Ammonia (green) acceptable if eye irritation

Greater than 300 ppm Supplied Air - prevented

Asbestos Less than 0.1f/cc None Required - 0.1f/cc 1.0 f/cc None
0.1 – 1.0 f/cc Half Mask HEPA (purple) Determined
1.1 f/cc – 10.0 f/cc Full Face HEPA (purple)
Greater than 10.0 f/cc Supplied Air -
Benzene Less than 0.5 ppm None Required - 1 ppm 5 ppm 500 ppm
0.5 - 10 ppm Half Mask OV (black or yellow)
11 – 50 ppm Full Face OV (black or yellow)
Greater than 50 ppm Supplied Air -
Butadiene (1,3-) Less than 1 ppm None Required - 1 ppm 5 ppm 2000 ppm
1 – 10 ppm Half Mask OV (black or yellow)
11 – 50 ppm Full Face OV (black or yellow)
Greater than 50 ppm Supplied Air -
Carbon Dioxide Greater than 5000 ppm Supplied Air - 5000 ppm 30,000 ppm 40,000 ppm Air purifying respirator is not appropriate
Carbon Monoxide Greater than 25 ppm Supplied Air - 25 ppm NA 1200 ppm Air purifying respirator is not appropriate
Chlorine Less than 0.5 ppm None Required - 0.5 ppm 1 ppm 10 ppm
0.5 – 5 ppm Full Face AG (white or yellow)
Greater than 5 ppm Supplied Air -
Chromium, Hexavalent Less than .005 mg/m 3
None Required - .005 mg/m3 None None
Determined Determined

.005 mg/m3 – 0.050 mg/m3 Half Mask HEPA (purple)

.051 mg/m3 – 0.25 mg/m3 Full Face HEPA (purple)
Greater than 0.25 mg/m3 Supplied Air -

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Title: PPE-5 Respiratory Protection Doc Number: RSW-000025-GB Rev No: 6

Attachment B: GBR Respirator Selection Matrix (2 of 3)

Contaminant Exposure level Respirator 1 Cartridge (color) 2 PEL/TLV 3, 6 STEL 4, 6 IDLH 5, 6 Notes
Inhalable Dust Less than 10 mg/m3 None Required - 10 mg/m3 None None Some dusts may contain metals
(not otherwise 10 – 100 mg/m3 Half Mask HEPA (purple) Determined Determined requiring more stringent respiratory protection.
classified)
101 – 500 mg/m3 Full Face HEPA (purple)
Greater than 500 mg/m3 Supplied Air -
Respirable Dust (not Less than 3 mg/m3 None required - 3 mg/m3 None None Some dusts may contain metals
otherwise classified) Determined Determined requiring more stringent respiratory protection.
3 mg/m3 – 30 mg/m3 Half Mask HEPA (purple)
31 mg/m – 150 mg/m Full Face HEPA (purple)
3 3

Greater than 150 mg/m3 Supplied Air -

Ethyl Benzene Less than 100 ppm None Required - 100 ppm 125 ppm 800 ppm Half mask at 500 ppm or less
100 – 500 ppm Half Mask OV (black or yellow) with appropriate eye protection
501 – 800 ppm Full Face OV (black or yellow) acceptable if eye irritation
Greater than 800 ppm Supplied Air - prevented
Hexane (n-) Less than 50 ppm None Required - 50 ppm None 1100 ppm Half mask at 500 ppm or less
50 – 500 ppm Half Mask OV (black or yellow) Determined with appropriate eye protection
501 – 1100 ppm Full Face OV (black or yellow) acceptable if eye irritation
Greater than 1100 ppm Supplied Air - prevented
Hydrochloric Acid Less than 5 ppm None Required - None (c) 5 ppm 50 ppm
5 – 25 ppm Half Mask AG (white or yellow) Determined
26 – 50 ppm Full Face AG (white or yellow)
Greater than 50 ppm Supplied Air -
Hydrofluoric Acid Less than 0.5 ppm None Required - 0.5 ppm (c) 2 ppm 30 ppm
Equal/Greater than 0.5 ppm Supplied Air -
Hydrogen Sulfide Less than 10 ppm None Required - 10 ppm 15 ppm 100 ppm See Hydrogen Sulfide policy to see protocol for
approving APRs for H2S use
Equal/Greater than 10 ppm Supplied Air -
Lead Less than 0.05 mg/m3 None Required - 0.05 mg/m3 None 100 mg/m3
0.05 – 0.50 mg/m3 Half Mask HEPA (purple) Determined
0.51 – 5.0 mg/m3 Full Face HEPA (purple)
Greater than 5.0 mg/m3 Supplied Air -
Methanol Less than 200 ppm None Required - 200 ppm 250 ppm 6000 ppm
Equal/Greater than 200 Supplied Air -
Nitrogen Dioxide Less than 3 ppm None Required - 0.2 ppm 5 ppm 13 ppm
Equal/Greater than 3 ppm Supplied Air -

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 Blanchard Refining Company LLC Galveston Bay Refinery
Title: PPE-5 Respiratory Protection Doc Number: RSW-000025-GB Rev No: 6

Attachment B: GBR Respirator Selection Matrix (3 of 3)

Contaminant Exposure level Respirator 1 Cartridge (color) 2 PEL/TLV 3, 6 STEL 4, 6 IDLH 5, 6 Notes
Sodium Hydroxide Less than 2 mg/m3 None Required - 2 mg/m3 (c) 2 mg/m3 10 mg/m3 Half mask at 20 mg/m3 or less
2 – 20 mg/m3 Half Mask HEPA (purple) with appropriate eye protection
21 – 200 mg/m3 Full Face HEPA (purple) acceptable if eye irritation
Greater than 200 mg/m3 Supplied Air - prevented
Styrene Less than 20 ppm None Required - 20 ppm 40ppm 700 ppm Half mask at 200 ppm or less
20 – 200 ppm Half Mask OV (black or yellow) with appropriate eye protection
201 – 700 ppm Full Face OV (black or yellow) acceptable if eye irritation
Greater than 700 ppm Supplied Air - prevented
Sulfur Dioxide Less than 2 ppm None Required - 2 ppm 5 ppm 100 ppm Half mask at 20 ppm or less
2 – 20 ppm Half Mask AG (white or yellow) with appropriate eye protection
21 – 100 ppm Full Face AG (white or yellow) acceptable if eye irritation
Greater than 100 ppm Supplied Air - prevented
Sulfuric Acid Less than 0.2 mg/m3 None Required - 0.2 mg/m3 N/A 15 mg/m3 Half mask at 2 mg/m3 or less
0.2 – 2 mg/m3 Half Mask HEPA & Acid Gas with appropriate eye protection
2 – 10 mg/m3 Full Face HEPA & Acid Gas acceptable if eye irritation
Greater than 10 mg/m3 Supplied Air - prevented
Toluene Less than 20 ppm None Required - 20 ppm (c) 300 ppm 500 ppm Half mask at 300 ppm or less
20 – 300 ppm Half Mask OV (black or yellow) with appropriate eye protection
301 – 500 ppm Full Face OV (black or yellow) acceptable if eye irritation
Greater than 500 ppm Supplied Air - prevented
Total Hydrocarbons Less than 300 ppm None Required - 300 ppm 500 ppm None Respiratory protection required
(not otherwise 300 to 1000 ppm Half Mask OV (black or yellow) Determined for certain hydrocarbon types
classified) 1001 – 3000 ppm Full Face OV (black or yellow) may be more stringent (i.e., benzene, hexane,
Greater than 3000 ppm Supplied Air - butadiene, toluene, xylenes, etc.)
Xylenes Less than 100 ppm None Required - 100 ppm 150 ppm 900 ppm Half mask at 500 ppm or less
100 to 500 ppm Half Mask OV (black or yellow) with appropriate eye protection
501 – 900 ppm Full Face OV (black or yellow) acceptable if eye irritation
Greater than 900 ppm Supplied Air - prevented
1
If the TCS location does not utilize full face air purifying respirators, then supplied air respirators shall be used within the designated full face respirator exposure concentration range
2
OV = organic vapor (black), AG = acid gas (white), OV/AG = organic vapor/acid gas (yellow), HEPA = high efficiency particulate air (purple)
3
PEL/TLV = average exposure allowed over an 8-hour period, 40 hour work week as established by the Occupational Safety and Health Administration (PEL = Permissible Exposure Limit) or
American Conference of Governmental Industrial Hygienists (TLV = Threshold Limit Value). The lower of the two exposure limits are followed by MPC in most cases and shown in the table
above.
4
STEL = Short Term Exposure Limit. The average exposure allowed over a 15-minute period as established by OSHA or ACGIH
5
IDLH = Immediately Dangerous To Life and Health. IDLH concentrations presented were set to ensure the worker can escape in the event of respiratory protection equipment failure.
6
c = ceiling value, f/cc = fibers per cubic centimeter, mg/m3 = milligrams per meter cubed, ppm = parts per million

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Attachment C: Air Purifying Respirator Cartridge Change-out Schedule

When no specific cartridge /canister change schedule is available, respirator

cartridges / canisters are to be discarded after each day’s use / at the end of shift.
Cartridges / canisters are to be replaced during the shift if breakthrough is perceived
(e.g. irritation, odor, symptoms, etc.) or if breathing through the filer media becomes
difficult.

The basis for the above cartridge / canister change schedule is 3M’s Service Life
Software utilized with conservative assumptions and expected worst-case maximum
concentrations for the contaminants of concern at this site.

Specific cartridge / canister change schedules can be developed if needed and upon
request.

For the details of this assessment, or to have a specific change schedule developed
contact the Safety Department.

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Attachment D: Galveston Bay Refinery Monthly Respiratory Protection Inspection Checklist

Unit/Area: __________________ Date: ____________ Inspected By: ______________________

To complete form, place a check ( √ ) if item is OK or an ( Χ ) if it needs repair.

Contact the warehouse at ext. 1631 if repairs are needed.

Fixed System (bottles and tubing manifold system) Yes No

Are all bottles open?
Is the block valve from the air cylinders open?
Is the bottle manifold pressure gauge showing at least 2000 psig?
Does the warning bell work?
Did the regulator(s) on the low pressure side hold pressure?
Are the fitting connections tight?

Supplied Air Respirator (SAR) Masks AIR AIR AIR AIR AIR AIR AIR AIR
and Hose Line Assembly PAK # PAK# PAK# PAK# PAK# PAK# PAK# PAK#

Is the egress cylinder full?

Are hose line connections tight and not
leaking?
Is the condition of the mask OK?
Are the mask straps extended?
Are the harness straps extended?
Is the lens in good condition?
Is the bypass valve closed?
Is the regulator and warning device
working?
Is the regulator shut off valve open?
Is the exhalation valve sticking closed?
Is the mask stored in a plastic bag?
Is the egress cylinder hydrostatic test date
in compliance?
Remarks

Inspection records shall be kept at each operating unit for one year.

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Title: PPE-5 Respiratory Protection Doc Number: RSW-000025-GB Rev No: 6

Attachment E: Respirator Cleaning Requirements

A. Remove filters, cartridges, or canisters. Disassemble facepieces by removing speaking

diaphragms, demand and pressure- demand valve assemblies, hoses, or any components
recommended by the manufacturer. Discard or repair any defective parts.
B. Wash components in warm (43 deg. C [110 deg. F] maximum) water with a mild detergent or with
a cleaner recommended by the manufacturer. A stiff bristle (not wire) brush may be used to
facilitate the removal of dirt.
C. Rinse components thoroughly in clean, warm (43 deg. C [110 deg. F] maximum), preferably
running water. Drain.
D. When the cleaner used does not contain a disinfecting agent, respirator components should be
immersed for two minutes in one of the following:
1. Hypochlorite solution (50 ppm of chlorine) made by adding approximately one milliliter of
laundry bleach to one liter of water at 43 deg. C (110 deg. F); or,
2. Aqueous solution of iodine (50 ppm iodine) made by adding approximately 0.8 milliliters
of tincture of iodine (6-8 grams ammonium and/or potassium iodide/100 cc of 45%
alcohol) to one liter of water at 43 deg. C (110 deg. F); or,
3. Other commercially available cleansers of equivalent disinfectant quality (i.e. respirator
wipes) when used as directed, if their use is recommended or approved by the respirator
manufacturer.
E. Rinse components thoroughly in clean, warm (43 deg. C [110 deg. F] maximum), preferably
running water. Drain. The importance of thorough rinsing cannot be overemphasized. Detergents
or disinfectants that dry on facepieces may result in dermatitis. In addition, some disinfectants
may cause deterioration of rubber or corrosion of metal parts if not completely removed.
F. Components should be hand-dried with a clean lint-free cloth or air-dried.
G. Reassemble facepiece, replacing filters, cartridges, and canisters where necessary.
H. Test the respirator to ensure that all components work properly.

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Title: PPE-5 Respiratory Protection Doc Number: RSW-000025-GB Rev No: 6

Attachment F: Typical Air Cylinder System for Field Use of Supplied Air
Respiratory Protective Equipment

MANIFOLD
ASSEMBLY MAY
SUPPLY UP TO TWO
WORKERS

NIOSH Approved Breathing Air Regulator Working Pressures

for Honeywell / Sperian / Survivair / Scott Supplied Air Respirators (SAR):
80 – 125 psig

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Attachment G: Contractors Required To Have a Respirator Program

TAR* Civil work (concrete, HVAC repair

Routine Process* sewer) Insulation work
Maintenance* Cooling tower (refractory, fire brick,
Boiler Repair Flare insulation)
Demolition Precipitator Pest control (weed,
Dock Repair Industrial Cleaning insects)
Drilling Pipeline construction Inspection work (tanks,
Tube Repair Machining NDT, etc)
Heat Tracing Leak Detection and/ or Vacuum trucks
Exchanger Repair Spill Cleanup
Painting Compressor repair Fire protection
Abrasive blasting Valve repair Emergency response
Tank work Laborers (attendants & Bulk Chemical Delivery
Hydroblasting firewatches) Drivers
Pump & Blower repair *If required by scope of work
I&E: transmitter work

Contractors Not Included & Not Required To Have A Respirator Program

Rail repair Elevator repair Crane repair

Rail switching Fence repair IT/DCS work
Re-railing Scale work Truck/delivery (except
Electrical (switchgear, Plumbing bulk chemical delivery
transformers, polelines) Consultants drivers)
Janitorial Rental companies

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Title: PPE-5 Respiratory Protection Doc Number: RSW-000025-GB Rev No: 6

Attachment H: Fresh Air Work Checklist

Date received: Supervisor Accepting Bottles: Wind Direction:

Location: Bottle Watch Name: Company:

Equipment Accepted: Back-Up Person Name (if IDLH):

Servicing Group Rep:

Name Signature Date

MPC Maintenance Supervisor:

(if contract work) Name Signature Date

Keep this form with SWP

Employees MUST have face to face discussion with Servicing Group Representative before task starts
If Escape Pack cylinder is opened Operations Supervisor MUST be notified

Cylinders and Associated Equipment Bottles/Rack Number:

Yes No Yes No
Bottles on level surface and secured Bottles placed upwind of job
≥ 5ft. radius barricaded in place before job begins Gauges working properly
All connections working properly Manifold attached at source
Work does not endanger others in immediate area
Manifold fittings inspected
or downwind
Permits completed and displayed at the job prior
Certificate of breathing air quality available.
to beginning work
Breathing air hoses are in good repair and have Ensure cylinders have adequate air for the job
been inspected (within 1 year). (see Attachment J).
Escape Pack
Yes No Yes No
Escape bottle is full Gauge working properly
Valve closed Hose in good condition
Harness is in good condition Quick disconnects locked
Snaps, buckles, clips in good condition
Bottle Watch/ and Back-Up Personnel
Yes No Yes No
Bottle Watch is qualified to do the job. Regulator-coupling secured
Bottle Watch knows to maintain operating pressure Bottle Watch knows unit alarm signals and
not to exceed 125 psi. evacuation route in unit
Bottle Watch tags any damaged equipment out of Bottle Watch has proper vest and air horn before
service job begins
Hose lines run in route of escape Alarm set at 500 psi and tested
Air hose ≤300 ft. per employee with low pressure
Bottle Watch knows to alert personnel at 600 psi
hose
Back-up personnel are wearing fresh air equipment Bottle Watch has clear view of employees or a way
and ready to hook up as needed (if IDLH) of communication with entry employee(s)
Communication plan established (radio, signal)
Respirator
Yes No Yes No
Mask type and size matches training/fit test card Fit check done before work begins
Lens is clean Mask seal is in good condition
Head straps adjust properly Adequate air flow
Purge valve closed
IF ANY STATEMENT IS “NO” – “STOP WORK” Re-assess job task.

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 Blanchard Refining Company LLC Galveston Bay Refinery
Title: PPE-5 Respiratory Protection Doc Number: RSW-000025-GB Rev No: 6

Attachment I: Breathing Air Compressor/Breather Box Checklist

Date: Location: Company:

Servicing Group Rep:

Name Signature Date

MPC Maintenance Supervisor:

(if contract work) Name Signature Date

Breathing Air Compressor Yes No Breather Box Yes No

Breathing air compressor and airline A “Breather Box” from the approved safety
system has been set up and use is being equipment supply contractor has been properly
supervised by an individual with adequate connected, a tag containing the most recent
training and experience to ensure the date of sorbent bed replacement and the
system is capable of reliably delivering signature of the person performing the change
Grade D breathing air throughout its use is in the Breather Box, and all filter change
and that all conditions of the NIOSH indicators are indicating Green.
certification are being met as found in the
respirator manufacturer’s instruction
manual.
Compressor is an oil-lubricated rotary The Breather Box is in the upright position
screw type equipped with a receiving tank during use and either the box or remote alarm
and a high temperature shut-off, or a has been positioned near enough to a
written exception has been issued. designated person who will be able to hear /
see the Carbon Monoxide (CO) alarm and who
will take immediate action to ensure the
workers leave the area and remove their
respirators in the event the CO alarm activates.
The type of oil used in the “air side” of the The “Breather Box” CO alarm has been tested,
compressor is as recommended by the the CO monitor has been turned to the “On”
manufacturer. position, and the alarm indicator light displays
the Green “Normal” condition.
Compressor is positioned in clean air, Respiratory equipment to be connected to the
away from process sewers, vents, and “Breather Box” is NIOSH certified.
equipment exhaust.
The area surrounding the compressor and Airlines connected to the “Breather Box” are
high-pressure hoses has been barricaded. NIOSH certified and have connectors
dedicated for breathing air systems.
The air supply connection to the breather Once workers have been connected to the
box has been properly secured to prevent system and air is flowing, the regulator on the
the connection from parting. Breather Box has been adjusted to the
pressure specified in the respirator’s
instructions given the length of hose and
cooling devices being used. In addition, air
flow through the CO monitor has been adjusted
to within the Green bar area on the flow meter.
An “after-cooler” has been located “Plant Air” shall not be used for breathing air
downstream of the compressor to remove under any circumstance.
heat and water vapor from the air.

IF ANY STATEMENT IS “NO” – “STOP WORK” Re-assess job task.

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Blanchard Refining Company LLC Galveston Bay Refinery
Title: PPE-5 Respiratory Protection Doc Number: RSW-000025-GB Rev No: 6

Attachment J: Breathing Air Calculation Guideline

1. Complete the following information to determine the volume of breathing air

required for the job when using breathing air cylinders as air source.

Number of people per shift requiring breathing air (A): _____________________

Number of hours working under air per shift (B): _____________________
Estimated job length (shifts) (C): _____________________

Air volume required = 240 cubic feet/hour* x (A) x (B) x (C)

2. Select the air source below that will provide the least number of cascades to
complete the job:

Air Source Volumes Number of Cascade Total Air (cubic feet)

Single cylinder (307 cubic feet)
2-cylinder cascade (614 cubic feet)
4-cylinder cascade (1228 cubic feet)
6-cylinder cascade (1842 cubic feet)
8-cylinder cascade (2456 cubic feet)
12-cylinder cascade (3684 cubic feet)
24-cylinder cascade (7368 cubic feet)
Small tube trailer (59,000 cubic feet)
Jumbo tube trailer (159,000 cubic feet)

* Reference: NIOSH Guide to Industrial Respiratory Protection, DHHS (NIOSH)

Publication No. 87-116

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Blanchard Refining Company LLC Galveston Bay Refinery
Title: PPE-5 Respiratory Protection Doc Number: RSW-000025-GB Rev No: 6

Attachment K: GBR Facial Hair Requirements

Mustache ends at the corner of the mouth and/or hair below the lower lip
must not be more than one half inch in length.

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Blanchard Refining Company LLC Galveston Bay Refinery
Title: PPE-5 Respiratory Protection Doc Number: RSW-000025-GB Rev No: 6

Attachment L: Information for Employees Using Respirators When Not Required

Under the Standard
29 C.F.R. 1910.134 Attachment D

Respirators are an effective method of protection against designated hazards when properly
selected and worn. Respirator use is encouraged, even when exposures are below the
exposure limit, to provide an additional level of comfort and protection for workers. However, if a
respirator is used improperly or not kept clean, the respirator itself can become a hazard to the
worker. Sometimes, workers may wear respirators to avoid exposures to hazards, even if the
amount of hazardous substance does not exceed the limits set by OSHA standards. If your
employer provides respirators for your voluntary use, or if you provide your own respirator, you
need to take certain precautions to be sure that the respirator itself does not present a hazard.

You should do the following:

1. Read and heed all instructions provided by the manufacturer on use, maintenance, cleaning
and care, and warnings regarding the respirator’s limitations.

2. Choose respirators certified for use to protect against the contaminant of concern. NIOSH,
the National Institute for Occupational Safety and Health of the U.S. Department of Health and
Human Services, certifies respirators. A label or statement of certification should appear on the
respirator or respirator packaging. It will tell you what the respirator is designed for and how
much it will protect you.

3. Do not wear your respirator into atmospheres containing contaminants for which your
respirator is not designed to protect against. For example, a respirator designed to filter dust
particles will not protect you against gases, vapors, or very small solid particles of fumes or
smoke.

4. Keep track of your respirator so that you do not mistakenly use someone else's respirator.

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Blanchard Refining Company LLC Galveston Bay Refinery
Title: PPE-5 Respiratory Protection Doc Number: RSW-000025-GB Rev No: 6

Attachment M: Picture of Breathing Air Line Tag

Breathing Air Line Tags are stocked in the E/W Plant Warehouse, Bay Plant Warehouse, and
can also be obtained from Total Safety at Bay Plant Safety Repair and from DNOW at the E/W
Plant Craft Building.

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