GENERAL SAFETY & ENVIRONMENTAL PROCEDURES



GENERAL SAFETY PROCEDURES

RESPIRATORY PROTECTION

Procedure Number: GSP-602

TABLE OF CONTENTS

RESPIRATORY PROTECTION – GSP-602

1.0 PURPOSE 4

2.0 SCOPE 4

2.1. Personnel and Activities Covered By This Procedure 4

2.2. Exemptions from This Procedure 4

2.3. Additional Requirements Not Covered By This Procedure 4

3.0 DEFINITIONS 5

4.0 PREREQUISITES 9

4.1. Training / Personnel Requirements 9

4.2. Equipment Requirements 10

4.3. Other Requirements 10

5.0 PROCESS OVERVIEW FOR RESPIRATORY PROTECTION 11

6.0 INSTRUCTIONS 12

6.1. Hazard Assessment and Work Area Monitoring 12

6.2. Selection of Respiratory Protection Equipment 12

6.3. Use of Respiratory Equipment — General 16

6.4. Use of a Single-Use Disposable Mask 17

6.5. Use of a Cartridge Respirators 17

6.6. Use of Airline Respirators with Escape Bottle 20

6.7. Use of Self Contained Breathing Apparatus (SCBA) 21

6.8. Inspection, Maintenance and Storage 22

7.0 ROLES AND RESPONSIBILITIES 23

7.1. Responsibilities of the Valero Manager (or designee) 23

7.2. Responsibilities of the Employee 23

7.3. Responsibilities of the Supervisor (or designee) 23

7.4. Responsibilities of the Designated HSE Representative (Respiratory Program Administrator) or designee 24

7.5. Responsibilities of the Person Designated To Train Employees 24

8.0 MEDICAL CERTIFICATION 24

9.0 RESPIRATOR FIT TESTING 25

10.0 REPORTING REQUIREMENTS 26

11.0 DOCUMENTATION 26

12.0 APPENDIX A – SAMPLE RESPIRATORY PROTECTION QUESTIONNAIRE (OSHA CFR 1910.134) 27

13.0 APPENDIX B RESPIRATORY PROTECTION CHECKLIST 31

14.0 TABLE 1 ACCEPTABLE FIT TESTING METHODS 36

15.0 APPENDIX C RESPIRATOR SELECTION CHART 37

PURPOSE

A uniform procedure must be followed in selecting and using respiratory protective devices. This document establishes the use, care, inspection, limitations, fit testing and training, and medical procedures to be followed for the use of such devices. In all cases, the recommendations of the manufacturer and/or the applicable standards must be followed. They must also:

• Describe procedures and equipment for protecting employees from respiratory hazards

• Instruct employees in proper respirator selection, use and maintenance

• Comply with OSHA standard 29 CFR 1910.134, Respiratory Protection

SCOPE

1 Personnel and Activities Covered By This Procedure

This procedure applies all personnel, company or contractor, working in or on Valero Terminaling and Distribution Company (Valero) owned, operated or maintained pipelines or facilities.

2 Exemptions from This Procedure

This procedure exempts areas or facilities operated or maintained by other companies, including other Valero Companies, where:

• The use of their procedure is required

• Their procedure meets the minimum requirements of Valero’s Respiratory Protection Procedure

• Valero employees have been trained in those procedures

3 Additional Requirements Not Covered By This Procedure

This procedure does not cover medical surveillance requirements for exposures above OSHA limits. Work in areas containing asbestos, benzene and lead has additional requirements. For asbestos requirements, refer to Safe Handling of Asbestos Containing Material. For benzene requirements, refer to Benzene Exposure Control. For lead requirements, contact the HSE representative.

DEFINITIONS

Airline Respirator

An air supplying respirator in which the respirable gas is not designed to be carried by the wearer (also known as supplied air respirators)

Air-Purifying Respirator

A respirator in which ambient air is passed through an air purifying element that removes the contaminants(s). Air is passed through the air-purifying element by means of the breathing action or by a blower.

Assigned Protection Factor (APF)

The expected workplace level of respiratory protection that would be provided by a properly functioning respirator or a class of respirators to properly fitted and trained users

Air-Supplying Respirator

A class of respirators that supply a respirable atmosphere, independent of the workplace atmosphere

Breakthrough

The penetration of a chemical vapor through filter cartridge. The quantity or extent of breakthrough during service life testing is often referred to as the percentage of the input concentration.

Cartridge

A container with a filter, sorbent, or catalyst, or a combination of these items, which removes specific contaminants from the air passed through the container

Certified

Evaluated and listed as permissible by the National Institute for Occupational Safety (NIOSH), the Mine Safety and Health Administration (MSHA), or the Bureau of Mines (BM)

Contaminant

A harmful, irritating, or nuisance airborne material

Demand Respirator

An air-supplying respirator that admits respirable gas to the face piece only when a negative pressure is created inside the face piece by inhalation

Designated Health, Safety and Environmental (HSE) Representative

The designated HSE representative will normally be the Respiratory Program Administrator (unless otherwise designated) and may be a Valero employee or group or it may be a contracted entity providing specialized services to assist in environmental, health, industrial hygiene, and safety compliance activities. Subject to corporate management approval, each facility may satisfy these responsibilities through a combination of in-house and outside contracted services.

Disposable Respirator

A respirator for which maintenance is not intended and that is designed to be discarded after excessive resistance, sorbent exhaustion, physical damage, or end-of-service life renders it unsuitable for use

Dust

An aerosol consisting of mechanically produced solid particles derived from the breaking up of larger particles. Dusts generally have a larger particle size when compared to fumes.

Escape Respirator

A respirator intended only for use during emergency egress from an emergency situation or hazardous atmosphere

Exposure Limit

The maximum allowable concentration of a contaminant in the air to which an individual may be exposed. These may be time-weighted averages, short-term limits, or ceiling limits

Filter

A component used in respirators to remove solid or liquid aerosol from the inspired air

Fit Check

A test conducted by the wearer to determine if the respirator is properly seated to the face

Fit Factor

A quantitative measure of the fit of a particular respirator to a particular individual

Fit Test

The use of a challenge agent to evaluate the fit of a respirator on an individual

Fume

Solid Aerosols formed by condensation of a gas or vapor. Fumes generally have a smaller particle size when compared to dusts.

Gas

A fluid that has neither independent shape nor volume and tends to expand indefinitely

Hazardous Atmosphere

An atmosphere that contains a contaminant in excess of the exposure limit, explosive limit, or that is oxygen deficient

High-Efficiency Filter

A filter that removes from the air 99.7% or more of the aerosols having a diameter of 0.3 microns or more

Immediately Dangerous to Life or Health (IDLH)

Any atmosphere that poses an immediate hazard to life or poses immediate irreversible debilitating effects on health

Negative Pressure Respirator

A respirator in which the air pressure inside the respiratory inlet covering is negative during inhalation with respect to the ambient air pressure

Valero Responsible Person

Valero Responsible Person means a person with specific training, knowledge and experience in the area for which the person has the responsibility and the authority to control the equipment and requirements outlined in this procedure. A Valero Responsible Person must be familiar with the construction and operation of the subject equipment and the associated hazards, and generally prepares the equipment in order to perform the necessary work.

Positive Pressure Respirator

A respirator in which the pressure inside the respiratory inlet covering is normally positive with respect to ambient air pressure

Powered Air Purifying Respirator

An air-purifying respirator that uses a blower to force the ambient atmosphere through air-purifying elements to the inlet covering

Pressure-Demand Respirator

A positive pressure air supplying respirator that admits respirable gas to the face piece when the positive pressure is reduced inside the face piece through inhalation

Qualitative Fit Test

A pass/fail fit test that relies on the subject’s sensory response to detect the challenge agent

Quantitative Fit Test

A fit test that uses an instrument to measure the challenge agent inside and outside the respirator. This is the “preferred” fit test for Valero sites.

Respiratory Program Administrator

Normally the HSE Representative or designee (see Responsibilities sec. 7.0)

Self-Contained Breathing Apparatus (SCBA)

An air-supplying respirator in which the respirable gas source is designed to be carried by the wearer

Manager

The management representative with overall responsibility for the pipeline, terminal, area, site or function

Supervisor or his Designated Representative

The management representative with immediate responsibility for the pipeline, terminal, area, site or function

Time-Weighted Average

The average concentration of a contaminant in air during a specific time period

Vapor

The gaseous phase of matter that normally exists in a liquid or solid state at room temperature

PREREQUISITES

1 Training / Personnel Requirements

All users of respirators must be given adequate initial and annual refresher training in accordance with OSHA 29 CFR 1910.134 (k).

Respirator users must be trained in the following:

1 The need for respiratory protection

2 Basic respiratory practices

3 The nature, extent, and effects of respiratory hazards at their location

4 The functions of the negative pressure and atmosphere supplying respirators, their use application and limitation

5 The correct manner of donning a respirator, including fitting instructions (positive/negative pressure check) with demonstration and practice.

The conditions which affect the mask to face seal including:

• Temple bars of eyeglasses

• Facial hair

• Goggles, hard hats, or other safety equipment

• Facial configurations

• The recognition and resolution of respirator use problems

• The principles and criteria for selecting respirators

• The procedures for medical approval, fit testing, and issuance

• The proper way to inspect, use, clean, sanitize, maintain, and store respirators

• The location of respirators for both routine and emergency use

• The location of the written respirator procedure

• The OSHA Standard on respirators (29 CFR 1910.134)

2 Equipment Requirements

Respirators selected must be approved by the National Institute for Occupational Safety and Health (NIOSH) and must be approved by the designated HSE representative.

3 Other Requirements

Valero's first priority is to control respiratory hazards by eliminating or minimizing exposure to the hazards. Methods of controlling these hazards, through engineering controls, should be investigated before requiring respiratory protection.

PROCESS OVERVIEW FOR RESPIRATORY PROTECTION

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INSTRUCTIONS

1 Hazard Assessment and Work Area Monitoring

The Valero Responsible Person initiates the hazard assessment process before work is performed in the area. The Valero Responsible Person considers historical data about the hazards of the work process or work site and considers what airborne contaminants could be present at the work site. Based on these considerations, the Valero Responsible Person initiates monitoring to determine actual concentration levels.

Atmospheres contain respiratory hazards when they:

1 Are oxygen deficient (23%)

2 Have airborne contaminant levels (or combinations of these) which exceed the Short Term Exposure Limit (STEL) or 8 hour Time Weighted Average (TWA) Permissible Exposure Limit (PEL)

3 Have gas or airborne contaminant levels which are immediately dangerous to life or health (IDLH)

The Valero Responsible Person ensures that the concentration level of respiratory hazards in the work area is monitored before respirator selection and periodically during respirator use to provide proper worker protection. Surveillance of the work area should be frequent enough to ensure no new respiratory hazards develop. The frequency is sometimes specified in other procedures such as Hot Work or Confined Space Entry.

The Valero Responsible Person contacts the designated HSE representative if assistance is needed in determining what hazards may be present, and in performing work area air monitoring.

Information regarding respiratory hazards and requirements for respiratory protection for a specific chemical is contained in the Personal Protective Equipment section of the Material Safety Data Sheet (MSDS). The Valero Responsible Person reviews MSDSs of hazardous materials that will be present in a work area or in a work procedure as part of determining what contaminant monitoring is required. Common airborne contaminants in the petroleum industry include methane, hydrogen sulfide, benzene, toluene, xylene, and particulates.

2 Selection of Respiratory Protection Equipment

The Valero Responsible Person selects the appropriate respiratory equipment by comparing the type and level of contaminants present to the type and protection factor of available respirators. This selection process is summarized in the Respirator Selection Process Flowchart in Appendix C and described in greater detail in the following sections.

Classifications of Respirators

There are four general classifications of respiratory protective equipment commonly used in Valero operations:

• Single use disposable dust mask

• Cartridge respirator

• Airline respirator

• Self contained breathing apparatus (SCBA)

Definitions of each are provided in section 2.0 of this procedure.

Protection Factors

Each respirator has limitations on the airborne level of contaminant it can protect against due to the potential for inward leakage around the face piece seal and other factors. For this reason the Protection Factors (PF) listed in Figure 602.1 are used for respirator selection.

NOTE: For asbestos use Figure 602.2, for benzene use Figure 602.3 or for lead use figure 602.4.

FIGURE 602.1

|Respirator |Protection |

| |Factor |

|Single Use or Disposable Dust Mask |5 |

|Half Mask Cartridge |10 |

|Full Face Cartridge |50 |

|Full Face Airline* |10,000 + |

|SCBA with full face mask* |10,000 + |

|* Indicates operating in positive pressure mode |

Example: A respirator with a Protection Factor of 10 can be used in an atmosphere containing up to 10 times the allowable exposure level of a contaminant, unless the contaminant level is IDLH. With the Protection Factor of the half mask, a person can work for eight hours in an environment with up to 10 ppm of a substance with a Permissible Exposure Level of 1 ppm.

FIGURE 602.2

|ASBESTOS PROTECTION FACTORS |

|Concentration |Respirator |

|0.5 mg/m3 or less (10 times PEL) |Half mask cartridge |

|2.5 mg/m3 or less (50 times PEL) |Full face cartridge |

FIGURE 602.3

|BENZENE PROTECTION FACTORS |

|Concentration |Respirator |

|10 ppm or less |Half mask cartridge |

|50 ppm or less |Full face cartridge |

|100 ppm or less |Full face powered cartridge |

|1000ppm or less |Full face supplied air respirator in positive pressure mode |

|Greater than 1000 ppm or unknown |Self contained breathing apparatus with full face piece in positive |

|concentration |pressure mode |

FIGURE 602.4

|LEAD PROTECTION FACTORS |

|Concentration |Respirator |

|2f/cc or less (10 times PEL) |Half mask cartridge |

|10f/cc or less (50 times PEL) |Full face cartridge |

WARNING: If concentrations exceed the levels listed above, contact HSE before continuing work or entering the hazardous atmosphere.

Single Use Disposable Dust Mask

The disposable dust mask provides protection against low levels of airborne dust. It is intended to be used and discarded at the end of a task or work day. A disposable dust mask should be selected for tasks such as sweeping floors, dumping bags of non-toxic materials, or sanding woods and metals. Disposable masks are not to be used for spray painting or for protection against gases or vapors.

WARNING: If an MSDS states "respiratory protection is required" or "should be used," a disposable dust mask may not be used.

Cartridge Respirator (air purifying respirator or APR)

The cartridge respirator cleans contaminated air by filtering the contaminant and/or absorbing it in chemical cartridges. The cartridge selection depends upon the type and concentration of the contaminant and the job to be performed. Cartridge respirators should be selected when all of the following four conditions are met:

Contaminants are present in concentrations above the 15 minute Short Term Exposure Limit or 8 hour Permissible Exposure Levels

Contaminant levels are within the protection factor for a cartridge respirator

Atmosphere is not oxygen deficient or enriched

Atmosphere is not IDLH

DANGER: Cartridge respirators are never to be used in oxygen deficient or IDLH atmospheres, nor for protection against hydrogen sulfide (H2S) or other contaminants where break-through can not be noticed.

Airline Respirator

Airline respirators (and airline respirators with escape bottle (only type allowed)) are generally used for planned work such as tank cleaning.

The Full Face Mask Airline Respirator provides respiratory protection against all airborne contaminants and provides full face protection. It has a self contained escape bottle and can be used in an IDLH atmosphere. The Full Face Mask Airline Respirator should be selected under any of the following conditions:

1 Atmosphere is oxygen deficient or enriched

2 Contaminant level is IDLH

3 Contaminant level exceeds the protection factor of a cartridge respirator

Self Contained Breathing Apparatus (SCBA).

SCBAs are generally used for short duration tasks such as gas testing inside a confined space, hand gauging a sour crude oil tank, handling emergencies, or for rescue. SCBAs should be selected under any of the following conditions:

1 Atmosphere is oxygen deficient or enriched

2 Contaminant level is IDLH

3 Contaminant level requires a protection factor greater than that provided by a cartridge respirator

3 Use of Respiratory Equipment — General

Inspection Prior to Use

Valero employees must inspect their respirators before and after each use. This inspection includes the following:

1 Inspect the equipment prior to use to assure all parts are present and in good working order

2 Put the mask on, adjust straps and check for openings between the mask seal and face, conduct a positive and negative pressure test

3 Do not wear the mask if anything (mustache, beard, glasses, etc.) prevents a good face seal

Use of Respirator in IDLH Atmospheres

Work in IDLH environments requires use of either an SCBA or an airline respirator with escape bottle (see section 6.2). Any use of respirators in IDLH atmospheres requires standby personnel with suitable rescue equipment (i.e., harness, lifeline, retrieval device or hoist, etc.)

Note: SCBA or supplied-air respirators are required in oxygen deficient atmospheres (i.e. nitrogen-purged vessels). Valero personnel are not permitted to enter flammable atmospheres (LEL >10%).

Listed are some examples of IDLH levels for chemicals found at Valero facilities:

|Contaminant |IDLH Level |

|H2S |>300 ppm |

|CO2 |>50,000 ppm |

|Lead |>700 mg/m3 |

5 Use of a Single-Use Disposable Mask

To use a single-use disposable mask:

• Follow the pre-use inspection steps in Section 6.3

• Adjust the straps so the fit is snug but comfortable

• Change the mask if the filter clogs or if the mask becomes damaged

NOTE: Specific requirements for service life may be indicated by the manufacturer. Check the label or consult the manufacturer for information about length of use and type of contaminants the mask is intended for. Some single-use respirators resemble half masks except that the cartridge and other parts cannot be replaced. For these respirators, use the Cartridge Respirator Instructions, section 6.5.

6 Use of a Cartridge Respirators

To use a cartridge respirator:

1 Follow the pre-inspection steps in Section 6.3.1

2 Choose the correct cartridge for the chemical involved

3 Perform positive and negative pressure fit checks (Section 6.5.2)

4 Replace inlet and outlet valves as necessary

NOTE: See section 6.5.3 and appendix C for cartridge selection.

5 Replace cartridges after each full shift use or more often if breathing becomes difficult or if chemical odor, taste, or irritations are noticed. Replace filters after a full shift or more often if the filter becomes clogged; a clogged filter makes it hard to breathe

6 After use, clean the mask with soap and warm water or appropriate disinfectant spray. Use a brush to remove dirt. Rinse and hang up to dry. Do not wear a mask that has been passed on to you unless it is clean

7 Store the mask to protect against dust, sunlight and extreme temperatures, excessive moisture, and damaging chemicals

Fit Check for Cartridge Respirators

Each time an employee puts on a full face or half mask respirator he/she must first test for a proper face piece-to-face seal by performing positive and negative pressure checks.

Negative Pressure Check

With the respirator positioned comfortably on the face and head-straps moderately tight, the wearer closes off the inlets of the cartridge by placing the palm of the hand over the inlets. With the respirator inlets sealed, the wearer inhales gently, creating a slight negative pressure in the face mask. The wearer should hold the breath for about five seconds. The face piece should remain slightly collapsed and no inward leakage should be detected. This test checks the respirator seal against the face and the function of the exhalation valves.

Positive Pressure Check

This test is similar to the one just described. The wearer closes off the exhalation valve with the palm of the hand and exhales gently into the face piece. A slight positive pressure should build up in the face piece and remain. This test checks the respirator seal against the face and the function of the inhalation valve.

Cartridge Selection

Filter cartridges can be used for protection against low levels of dusts, fumes and mists, while chemical cartridges can be used for protection against organic vapors, acid gases, and other specific contaminants. Several different cartridges are available for some masks depending on the toxicity of the contaminant. Choose the proper cartridge based on the exposure limit of the contaminant. The label on the cartridge indicates the contaminant(s) the cartridge is approved for.

|Atmospheric Contaminant |Color Assigned to Cartridges |

|Organic Vapors |Black |

|Acid Gases and Organic Vapors |Yellow |

|Radioactive Material (excepting Tritium and Noble Gases), |Purple (Magenta) |

|Asbestos, Lead, and Welding Fumes | |

Because of their poor warning properties (break-through cannot be noticed), do not use cartridge respirators for:

• CO2

• CO

• H2S

• Vinyl Chloride

Gas and Vapor Cartridges

These offer limited protection in environments with high concentrations of gases or vapors and are for use only with chemicals that have good odor warning properties. Chemical cartridge respirators must be selected for the specific contaminant, or groups of contaminants, as recommended by the manufacturer. Leave the area immediately if you smell the chemical.

Dust, Fume, and Mist Cartridges

These do not provide protection against gases or vapors. Cartridges should be replaced when breathing resistance becomes noticeably uncomfortable.

7 Use of Airline Respirators with Escape Bottle

To use an airline respirator, always use it with an escape bottle:

1 Follow the pre-inspection steps in Section 6.3.

2 Inspect all equipment before each use to assure all parts are present and in good working order.

3 If using a compressor, make sure the air supply inlet is in an uncontaminated area. Use air purifying filters and sorbents on the compressor airline if needed. The air receiver must have sufficient capacity to enable escape from the contaminated area. If the compressor is oil lubricated, carbon monoxide or high temperature alarms are required. Make sure compressor failure and other alarms work properly.

4 Don the mask and adjust the straps so the fit is snug but comfortable. Check for leaks by covering the air inlet with your palm and inhaling gently. Hold your breath for 5 seconds. A good fit is indicated if the mask remains collapsed toward your face while holding your breath.

5 Connect the mask to the regulator.

6 In case of malfunction, leave the contaminated area immediately.

7 Check that the escape bottle is full. Make sure the air supply is sufficient to permit safe escape from the work area

8 Keep the cylinder valve closed during normal operations. Open the valve only when the airline supply is interrupted. This assures a full bottle for escape

9 Leave the area immediately if the airline supply fails or if you feel ill from diminished air capacity.

10 After use, clean the mask with cleaning solution and warm water or appropriate disinfectant spray. Use a brush to remove dirt. Clean regulator and air hose. Rinse and hang up to dry.

11 Inspect the unit before returning it to storage. Refer to manufacturer's instructions for further information. Repair any damaged equipment immediately.

WARNING: Never use an escape bottle by itself. Always use the escape bottle with an airline respirator. The bottle is for emergency escape only.

8 Use of Self Contained Breathing Apparatus (SCBA)

To use an SCBA:

1 Follow the pre-inspection instructions in Section 6.3.1.

2 Inspect the unit before each use, making sure air supply is adequate. A full 2,200 lb. cylinder should contain at least 1,600 lbs. of pressure.

3 Open the cylinder air supply valve. The low level alarm rings at 500 lbs. If the alarm does not sound when opening the supply valve, do not use the unit.

4 Don the unit so the cylinder is on your back with the valve pointing down. Hook the harness and tighten.

5 Don the mask and adjust it for a snug but comfortable fit. Test the fit by closing the hose and inhaling gently. Hold breath for 5 seconds; if the mask remains collapsed to your face, the seal is good.

6 Connect mask hose to regulator, making sure the regulator supply valve is open.

7 If airflow is insufficient due to regulator failure or other factors, open the bypass valve to obtain additional flow and leave the area immediately.

8 When the alarm sounds or in the event of any malfunction, leave the area immediately. When the alarm rings, the cylinder should have about 500 lbs. of pressure remaining.

9 After use, wash the face piece with soap and warm water or appropriate disinfectant spray. Also wash other parts that are soiled or contaminated. Use a brush to remove dirt. Rinse and hang up to dry. Refer to the manufacturer's instructions for additional information.

10 Have the bottle refilled with breathing air meeting at least the specification for Grade D breathing air in Compressed Gas Association. Do not use oxygen.

11 Repack the unit in good operating condition. Be sure to let the straps out to their full extent so the SCBA is ready to be used again in emergency service.

9 Inspection, Maintenance and Storage

Inspection

There are three respiratory equipment inspection requirements:

1 Each respirator that is not routinely used and is stored for emergency or rescue use must be inspected after each use and once per month. This applies to both SCBAs and cartridge respirators stored for emergency purposes, i.e., spill response, rescue.

2 SCBA units that are used routinely in a facility must also be inspected monthly.

3 Oxygen content of compressed air bottles for SCBAs must be verified whenever the bottles are refilled.

Document inspections for SCBAs and for cartridge respirators. The SCBA form must include space for documenting oxygen content of compressed air bottles. These checklists should be used in conjunction with the manufacturer’s instructions to ensure that respirators continue to function properly and that necessary inspection records are retained.

WARNING: Under no circumstances should a respirator that fails these inspections be used. The respirator should be repaired or replaced immediately. No attempt should be made to replace component parts or to make adjustments or repairs beyond the manufacturer's recommendations. Repairs should be performed only by employees or contractors knowledgeable of respirator use, function and repair.

Storage

Respirators must be stored in a convenient, clean and dry location (i.e., zip-lock freezer bag, cabinet) protected from heat, extreme cold, excessive moisture, or damaging chemicals. Equipment for emergency use should be quickly accessible and should be stored in clearly marked cabinets or cases.

ROLES AND RESPONSIBILITIES

1 Responsibilities of the Valero Manager (or designee)

The Valero Manager is responsible for:

1 Ensuring that all personnel are knowledgeable of the respiratory protection requirements on a specific project

2 Committing the organizational, motivational and financial resources to develop, implement, and maintain an effective Respiratory Protection Program

3 Enforcing the use of respirators where required on a specific project

2 Responsibilities of the Employee

The Employee is responsible for:

1 Following the respiratory protection requirements for their work areas as explained by their supervisor and described within this procedure

2 Inspecting the respirator before and after each use and replacement if not in proper condition

3 Clean and sanitize reusable airline and negative pressure respirator face masks

4 Advising their supervisor of any change in working conditions that might have an adverse affect on their health (i.e., new or unusual odors, vapors, mists, dusts, leaks, etc.)

5 Be clean shaven in the areas between the mask sealing surface and the facial skin when using tight fitting respirators

6 Advising their supervisor of any change in their health status that might affect their medical clearance to use a respirator and of any change in facial structure that might require a new fit test (i.e., scarring, dental surgery or dentures, etc.)

3 Responsibilities of the Supervisor (or designee)

The Supervisor or designee is responsible for:

1 Ensuring that all personnel are knowledgeable of the respiratory protection requirements for the areas in which they work

2 Ensuring that employees are required to wear respirators in their areas of responsibility are medically certified, fit tested, trained, and clean shaven

3 Ensuring that employees wear the proper respirators in their areas of responsibility

4 Ensuring that required inspections are performed and records retained

4 Responsibilities of the Designated HSE Representative (Respiratory Program Administrator) or designee

The designated HSE Representative will serve as the respiratory program administrator (unless otherwise designated) and is responsible for:

1 Developing, administering, and updating the written respiratory protection procedure

2 Assisting with hazard assessment and monitoring by providing information, instruction, or direct assistance at the work site

3 Providing information on related issues such as benzene protection, confined space entry, medical certification, etc.

4 Assisting supervision and production personnel in the proper selection of respiratory protection

5 Fit testing employees on the respirators that they will be required to wear

6 Developing and keeping current a respiratory protection program for the location

7 Ensuring that all respiratory protective equipment is inspected

8 Maintaining a detailed list of all respiratory protective equipment

5 Responsibilities of the Person Designated To Train Employees

Supervisor or designated trainer is responsible for:

1 Scheduling initial and annual respiratory protection procedure training to all affected employees as necessary

2 Maintaining employee records

MEDICAL CERTIFICATION

Personnel must not be assigned to tasks requiring the use of respirators for emergency, routing, or occasional use unless they have been determined by a physician or medical professional to be physically able to perform under such conditions. A physical examination must include, among other things as determined by the medical department, a pulmonary function test.

Medical approval for respirator use by employees must be determined by an appropriate medical professional.

Each employee is required to complete a medical history by the examining medical professional. An example of the medical questionnaire to be used can be found in APPENDIX A.

At a minimum, the medical professional evaluation must follow the guidelines listed in ANSI Z88.

After the examination, the medical professional must classify the examinee in a category which should reflect:

1 No restrictions on respirator use

2 Some specific restrictions

3 No respirator use under any circumstances

Medical confidentiality must be maintained in the communication to the HSE Group and terminal supervisor, in documentation of the approval or restrictions of respirator use.

Once a determination has been made as to the physical ability to wear a respirator and perform the work task(s), a review of the employee’s health status must be made periodically at the time of the annual fit test.

RESPIRATOR FIT TESTING

All employees that are required to use a respirator must be fit tested annually (or more frequently if employee physical conditions have changed since the last fit test) on the respirator models they will be using in the performance of their jobs. Loose fitting respirators (e.g. abrasive blasting hoods or helmets, escape paks, etc.,) do not require a fit test. A QUANTITATIVE Fit Test is the preferred method to be used for Valero employees.

Contractors and visitors are permitted to use either a qualitative or quantitative fit test as permitted by OSHA 29 CFR 1910.34 and 1926.103, or applicable regulated material standards (i.e., benzene, asbestos, lead, etc.)

Fit test protocols specified by OSHA must be used, along with those of the manufacturer of the quantitative fit testing equipment.

A respirator must be considered to have a good seal during the fit test if the following conditions are met:

1 There are no interferences to the mask sealing surfaces. Interferences such as eyeglass temple bars, prescription eyeglasses, facial or head hair, chemical goggles, hard hats and face shields can reduce the respirator sealing efficiency.

2 The fit test must be conducted with the normal safety equipment worn by the individual. This is necessary since the respirator seal may be affected by the adjustment of the respirator to accommodate other safety equipment.

The following lists requirements for meeting the “clean shaven” criteria while wearing tight fitting respirators:

3 No facial hair (beards, goatees, excessive stubble) may be worn

4 Mustaches, sideburns, or other facial hair are not permitted in areas which may cause interference with the sealing surface of the respirator.

5 In general, the following examples of facial hair growth are not acceptable:

THE PICTURES SHOWN BELOW ARE PROVIDED TO PORTRAY EXAMPLES OF HAIR STYLES WHICH ARE NOT ACCEPTABLE.

[pic]Example 9.1

Vision Correction - Employees needing vision correction with full face respirators will be provided with “insert” style prescriptions glasses by the Facility Manager or the HSE group.

REPORTING REQUIREMENTS

Deficiencies in monthly respiratory inspection must be communicated to the Supervisor for follow-up and resolution.

DOCUMENTATION

Respiratory inspection checklist must be conducted monthly and retained for 2 years. Examples of appropriate Respiratory inspection (in conjunction with OSHA requirements) can be found in Appendix B. Deficiencies must be documented and reported to the Terminal Supervisor or Manager.

APPENDIX A – SAMPLE RESPIRATORY PROTECTION QUESTIONNAIRE (OSHA CFR 1910.134)

COMPLETED FORM TO MEDICAL

The safe and effective use of respiratory protection is in part dependent on your state of health. Every employee who has been selected to use any type of respirator must provide the following information.

Please Print Clearly: Date:

Employee Number/SSN: Sex: Age: Height: Weight: lbs

Dept/Area: Work Phone: ( ) Title:

( Fire Brigade ( Fire/Rescue/Hazmat ( EMT's Site:

Have you previously worn a respirator? ( Yes, type(s):

Type respirator you will use: (Check all that apply) N / R / P / Disposable filter

( Half face ( Full Face ( Powered-air purifying ( Supplied-air ( Self-contained Breathing Apparatus

Are you required to wear other PPE that could affect your ability to use a respirator? ( No ( Yes,

Type:

|Please Check: ( |Yes |No |

|1. Do you smoke tobacco, or have you smoked in the last month? |( |( |

|2. Have you ever had any of the following conditions? |

| a. Seizures (fits) |( |( |

| b. Diabetes (sugar disease) |( |( |

| c. Allergic reactions that interfere with your breathing |( |( |

| d. Claustrophobia (fear of closed-in places) |( |( |

| e. Trouble smelling odors |( |( |

|3. Have you ever had any of the following lung conditions? |

| a. Asbestosis |( |( |

| b. Asthma |( |( |

| c. Chronic Bronchitis |( |( |

| d. Emphysema |( |( |

| e. Pneumonia |( |( |

| f. Tuberculosis |( |( |

| g. Silicosis |( |( |

| h. Collapsed lung |( |( |

| i. Lung cancer |( |( |

| j. Broken ribs |( |( |

| k. Any chest injuries or surgeries |( |( |

| l. Any other lung problem you are aware of? |( |( |

|Please Check: ( |

|Yes |

|No |

| |

|4. Do you have any of the following lung illnesses? |

| a. Shortness of breath |( |( |

| b. Shortness of breath when walking fast on level ground or walking up a slight hill or incline |( |( |

| c. Shortness of breath when walking with other people at an ordinary pace on level ground |( |( |

| d. Having to stop for breath when walking at your own pace on level ground |( |( |

| e. Shortness of breath when washing or dressing yourself |( |( |

| f. Shortness of breath that interferes with your job |( |( |

| g. Coughing that produces phlegm (thick sputum) |( |( |

| h. Coughing that wakes you early in the morning |( |( |

| i. Coughing that occurs mostly when you are lying down |( |( |

| j. Coughing up blood |( |( |

| k. Wheezing |( |( |

| l. Wheezing that interferes with your job |( |( |

| m. Chest pain when you breathe deeply |( |( |

| n. Any other symptoms that you think may be related to lung problems |( |( |

|5. Have you ever had any of the following heart problems? |

| a. Heart attack |( |( |

| b. Stroke |( |( |

| c. Angina |( |( |

| d. Heart failure |( |( |

| e. Swelling in your legs or feet (not caused by walking) |( |( |

| f. Heart beating irregularly |( |( |

| g. High blood pressure |( |( |

| h. Any other heart problem that you've been told about? |( |( |

|6. Have you ever had any of the following heart symptoms? |

| a. Frequent pain or tightness in your chest |( |( |

| b. Pain or tightness in your chest during physical activity |( |( |

| c. Pain or tightness in your chest that interferes with your job |( |( |

| d. In the past two years, have you noticed your heart skipping or missing a beat |( |( |

| e. Heartburn or indigestion that is not related to eating |( |( |

| f. Any other symptoms that you think may be related to heart or circulation problems? |( |( |

|Please Check: ( |Yes |No |

|7. Do you currently take medication for any of the following problems? |

| a. Breathing or lung problems |( |( |

| b. Heart trouble |( |( |

| c. Blood pressure |( |( |

| d. Seizures (fits) |( |( |

| e. Others (please list all medications) |

| |

| |

| |

|8. If you've used a respirator, have you ever had any of the following? (If you've never used a respirator go to question 9) |

| a. Eye irritation |( |( |

| b. Skin allergies or rashes |( |( |

| c. Anxiety |( |( |

| d. General weakness or fatigue |( |( |

| e. Any other problem that interferes with your use of respirator |( |( |

|9. Would you like to talk with the health care professional who will review this questionnaire?|( |( |

|Contact your supervisor for the number. | | |

| Questions 10 to 15 must be answered by every employee who has been selected to use either a full face or a self-contained breathing |

|apparatus (SCBA) For other types of respirators, answering these following questions is voluntary. |

|10. Have you ever lost vision in either eye, temporarily or permanently? |( |( |

|11. Do you currently have any of the following vision problems? |

| a. Wear contact lenses |( |( |

| b. Wear glasses |x |( |

| c. Color blind |( |( |

| d. Any other eye or vision problem |( |( |

|12. Have you ever had an injury to your ears, including a broken ear drum? |( |( |

|13. Do you currently have any of the following hearing problems? |

| a. Difficulty hearing |( |( |

| b. Wear a hearing aid |( |( |

| c. Any other hearing or ear problem |( |( |

|14. Have you ever had a back injury |( |( |

|15. Do you currently have any of the following musculoskelatal problems? |

| a. Weakness in your arms, hands, legs, or feet |( |( |

| b. Back pain |( |( |

| c. Difficulty moving your arms and legs. |( |( |

| d. Pain or stiffness when you lean forward or backward at the waist |( |( |

| e. Difficulty moving your head up or down |( |( |

| f. Difficulty moving your head side to side |( |( |

| g. Difficulty bending at your knees |( |( |

| h. Difficulty squatting to the ground |( |( |

| i. Difficulty climbing a flight of stairs or a ladder carrying more than 25 lbs. |( |( |

| j. Any other muscle or skeletal problem that interferes with using a respirator? |( |( |

Employee comments or explanation of above answers: ______________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

___________________________________________ ____________________

Employee Signature Date

FOR MEDICAL USE ONLY

( Medically cleared for respirator use

R. N. Date:

( Physician review required

( Medically cleared for respirator use

M. D. Date:

( Restrictions (See comments below)

( This employee is medically unfit for respirator use.

COMMENTS:

APPENDIX B RESPIRATORY PROTECTION CHECKLIST

| |Respiratory Protection Checklist | |

|Frequency: Program - Regular, Respirators - After each use, monthly |

|Inspection Team: |Responsible Personnel: |

|Location: |Department: |Area: |

|General: Respiratory protection must be provided to protect employees from dangerous dusts, fogs, fumes, mists, |

|gases, smokes, sprays or vapors. The primary objective must be to prevent atmospheric contamination. |

|[pic] |

|Note: Inspection checklists cannot possibly cover all the items and situations which may be encountered in the |

|workplace. Thus, this list can only serve as a guide. Refer to the References on Page 3 for more information and |

|details as well as other reference sources. |

|Item Number |Inspection Item |Standard Number |Yes |No |Comments |

|1           |Are employees who use a respirator |1910.134 (c)(2)(i) |  |  |  |

| |voluntarily provided with the information | | | | |

| |in Appendix D? | | | | |

|  |NOTE: NIOSH approved respirators are | | | | |

| |strongly recommended but not required for | | | | |

| |voluntary use. | | | | |

|2           |Has a Program Administrator been appointed?|1910.134 (c)(3) |  |  |  |

|3           |Have respiratory hazards been evaluated and|1910.134 (d) |  |  |  |

| |all relevant workplace and user factors | | | | |

| |been identified? | | | | |

|4           |Has the appropriate respirator been |1910.134 (d)(1)(i) |  |  |  |

| |selected? | | | | |

|5           |Are only NIOSH-certified respirators |1910.134 (d)(1)(ii) |  |  |  |

| |approved for use? | | | | |

|6           |Has a change schedule for cartridges and |1910.134(d)(3)(iii)(2) |  |  |  |

| |canisters been implemented that will ensure| | | | |

| |that canisters and cartridges are changed | | | | |

| |before the end of their service life? Is | | | | |

| |the information or data relied upon as the | | | | |

| |basis for change schedule been documented? | | | | |

|7           |Are medical evaluations conducted before |1910.134 (e)(1) |  |  |  |

| |fit testing or required use? | | | | |

|  |NOTE: These evaluations are required for | | | | |

| |all respirator users except voluntary use | | | | |

| |of dust masks and for escape-only | | | | |

| |respirators. SCBA’s are not considered | | | | |

| |escape-only respirators. | | | | |

|8           |Has a physician or other licensed |1910.134 (e)(2)(i) |  |  |  |

| |healthcare professional (PLHCP) been | | | | |

| |identified to perform medical evaluations? | | | | |

|9           |Does the medical evaluation obtain the |1910.134(e)(2)(ii) |  |  |  |

| |required information contained in the | | | | |

| |questionnaire in Part A of Appendix C? | | | | |

|Item Number |Inspection Item |Standard Number |Yes |No |Comments |

|10       |Has the employee been provided a written |1910.134(e)(6)(i) |  |  |  |

| |copy of the PLHCP's written recommendation | | | | |

| |regarding the employee's ability to wear a | | | | |

| |respirator? | | | | |

|11       |Have employees who use a tight-fitting |1910.134 (f)(1) |  |  |  |

| |facepiece respirator passed an appropriate | | | | |

| |qualitative (QLFT) or quantitative fit test| | | | |

| |(QNFT) prior to initial use of the | | | | |

| |respirator? (See Table 1) | | | | |

|12       |Have employees who use a tight-fitting |1910.134 (f)(1) |  |  |  |

| |facepiece respirator passed an appropriate | | | | |

| |qualitative (QLFT) or quantitative fit test| | | | |

| |(QNFT) prior to initial use of the | | | | |

| |respirator? (See Table 1) | | | | |

|13       |Are employees who use a tight-fitting |1910.134 (f)(2) |  |  |  |

| |facepiece respirator retested annually and | | | | |

| |whenever a different respirator facepiece | | | | |

| |(size, style, model or make) is used? | | | | |

|14       |Are procedures for the proper use of |1910.134 (g) |  |  |  |

| |respirators followed? | | | | |

|15       |Are employees who have the facial hair (one|1910.134 (g)(1)(i)(A) - (B) |  |  |  |

| |day’s growth) or any other condition that | | | | |

| |may interfere with the sealing surface of | | | | |

| |the facepiece or with valve function not | | | | |

| |permitted to respirators with tight-fitting| | | | |

| |facepieces? | | | | |

|16 |Do corrective glasses, goggles, or other |1910.134 (g)(1)(ii) |  |  |  |

| |personal protective equipment interfere | | | | |

| |with the seal of the facepiece to the face | | | | |

| |of the user? | | | | |

|17 |Are the requirements for entering an IDLH |1910.134 (g)(3) |  |  |  |

| |atmosphere followed? | | | | |

|18 |Are the employee(s) located outside the |1910.134 (g)(3)(vi) |  |  |  |

| |IDLH atmosphere equipped with appropriate | | | | |

| |equipment? | | | | |

|Item Number |Inspection Item |Standard Number |Yes |No |Comments |

|19 |Are the requirements for fighting an |1910.134 (g)(4) |  |  |  |

| |internal structural fire followed (two | | | | |

| |employees in—two employees out)? | | | | |

|20 |Are respirators in good working order? |1910.134 (h)(1) |  |  |  |

|21 |Are respirators stored to protect them from|1910.134(h)(2)(i) |  |  |  |

| |damage, contamination, dust, sunlight, | | | | |

| |excessive moisture and damaging chemicals? | | | | |

|22 |Are respirators cleaned and disinfected at |1910.134 (h)(1) |  |  |  |

| |the appropriate intervals? | | | | |

|23 |Are inspection guidelines followed? |1910.134 (h)(3)(i) |  |  |  |

|24 |Are emergency use only respirators |1910.134 (h)(3)(iv)(A) and |  |  |  |

| |certified? Is documentation of inspection |(B) | | | |

| |available? | | | | |

|25 |Does compressed and liquid oxygen meet the |1910.134 (i)(1)(i) |  |  |  |

| |U.S. Pharmacopoeia requirements for medical| | | | |

| |or breathing oxygen? | | | | |

|26 |Does compressed breathing air meet at least|1910.134 (i)(1)(ii) |  |  |  |

| |the requirements for Type 1-Grade D | | | | |

| |breathing air? | | | | |

|27 |For cylinders of purchased breathing air, |1910.134 (I)(4)(ii) |  |  |  |

| |is a certificate of analysis from the | | | | |

| |supplier available stating that the | | | | |

| |breathing air meets requirements for Type | | | | |

| |1-Grade D breathing air? | | | | |

|28 |Are all filters, cartridges, and canisters |1910.134 (j) |  |  |  |

| |used in the workplace labeled and color | | | | |

| |coded with a NIOSH approval label? | | | | |

|29 |Are employees who are required to wear |1910.134 (k) |  |  |  |

| |respirators trained prior to use in the | | | | |

| |workplace? | | | | |

|30       |Are the employees retrained annually or |1910.134 (k)(5) |  |  |  |

| |when a change, inadequacy, or any other | | | | |

| |situation arises? | | | | |

|Item Number |Inspection Item |Standard Number |Yes |No |Comments |

|31 |Are evaluations of the workplace conducted |1910.134 (l)(1) |  |  |  |

| |by the Program Administrator? | | | | |

|32 |Is written information regarding medical |1910.134 (m) |  |  |  |

| |evaluations, fit testing, and the | | | | |

| |respirator program established and retained| | | | |

| |and made available? | | | | |

|33 |NOTE: The old standard 1910.134 will be |  |  |  |  |

| |re-designated as 1910.139 and will apply | | | | |

| |only to respiratory protection against | | | | |

| |M.tuberculosis (TB) until OSHA promulgates | | | | |

| |a new and final standard. | | | | |

|References |  |  |  |  |

|1.       OSHA 29 CFR 1910.134 |

|2.       CPL 2-0.120 Inspection Procedure for the Respiratory Protection Standard |

|3.       NIOSH Respirator Certification Requirements 42 CFR 84 and 30 CFR 11 |  |

|Submitted by: |Date: |Time: |  |

|Submitted to: |Assigned to: |Date: |  |

TABLE 1 ACCEPTABLE FIT TESTING METHODS

APPENDIX C RESPIRATOR SELECTION CHART

Respirators must be selected from two general classes, air-purifying and air-supplying

-----------------------

Loose Hood Respirator

Powered Air or Cartridge Respirator

Airline

Respirator with escape bottle

SCBA

Airline w/Escape Bottle

Not Immediately Dangerous to Life

Immediately Dangerous to Life

Airline w/Escape Bottle

Gaseous or Particulate

SCBA

Hazardous Chemical

Oxygen Deficiency

Hazard

Table 1 | |Acceptable Fit-Testing s to Life

Immediately Dangerous to Life

Airline w/Escape Bottle

Gaseous or Particulate

SCBA

Hazardous Chemical

Oxygen Deficiency

Hazard

Table 1 | |Acceptable Fit-Testing Methods | |  |Qualitative Fit Test |Quantitative Fit Test | |•          Half-Face, Negative Pressure, APR (100 fit factor) |No |Yes | |•          Supplied-Air Respirators (SAR), or SCBA used in Positive Pressure (Pressure Demand Mode) |Yes |Yes | |•          SCBA - Structural Fire Fighting, Positive Pressure |Yes |Yes | |•          SCBA/SAR - IDLH, Positive Pressure |Yes |Yes | |•          Mouthbit Respirators |Fit-testing Not Required | |•          Loose-fitting Respirators (e.g., hoods, helmets) |Fit-testing Not Required | |

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