4Q1.7-216.pdf

Manual: 4Q1.7 Procedure: 216 Revision: 6

INSTRUCTIONS FOR THE INSPECTION AND REPAIR

OF THE MSA ULTRA TWIN RESPIRATOR

Effective Date: 08/03/2017 Type-Class: Tech-REF Page: 1 of 19

1.0 INTRODUCTION

1.1 Purpose

This procedure provides instructions for inspection and repair of the MSA Ultra Twin Respirator.

1.2 Scope

This procedure applies to the inspection and repair of air purifying MSA Ultra Twin Respirators in the Respiratory Equipment Facility (REF) by personnel who are authorized to perform these inspections and repairs.

This is a Reference procedure. The user is not required to have this procedure present while performing the activity.

The following data/round sheets may be utilized in the performance of this procedure:

OSR 4-510, Respiratory Equipment Record and QA

2.0 GENERAL INFORMATION

2.1 Definitions and Abbreviations

NC - New Cartridge; cartridges are marked NC to show that the respirator will be used for a non-radiological job. Any cartridges returned to the REF marked “NC” are not reused.

NIOSH - National Institute for Occupational Safety and Health

2.2 Responsibilities

1. The REF Lead is responsible for:

Evaluating results of OSR 4-510 to determine if significant defective items are reported and notifying the Respiratory Protection Program Administrator

(RPPA)

Initiating and responding to Nonconformance reports in accordance with Manual 1Q, Procedure 15-1, Control of Nonconforming Items

Defining acceptable condition of rust or discoloration on respirator parts.

2. Respiratory Equipment Facility (REF) Personnel are responsible for:

Performing respirator inspections and repairs (excluding the Savannah River Site Fire Department respirators)

Completing qualification training as specified in the Job Performance Standard or approved equal

Tracking quantity of products inspected, defective, repaired, rejected and new products put in service and recording information daily on OSR 4-510.

Instructions for the Inspection and Repair of the MSA Ultra Twin Respirator

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2.2 Responsibilities, (cont.)

3. The Respiratory Protection Program Administrator (RPPA) is responsible for:

Approving the release of respirators offsite

Responding to issues where significant defects are found.

2.3 Information

1. Respirator equipment is worn by workers for protection against airborne hazardous materials and must be maintained in like-new condition to ensure maximum respiratory protection.

2. Respiratory Equipment Facility personnel repair air purifying and air supplied respiratory equipment at Building 705-C.

2.3.1 Cartridges

1. Cartridges marked New Cartridge (NC) should be disposed of at the job site.

Any cartridges returned to the REF marked NC are not to be reused and should be returned to the laundry for proper disposal.

2.3.2 Respirator Size

1. Medium respirator nosecups are used in small respirators. Medium and large respirator nosecups are used in medium and large respirators. The site does not use small nosecups in the respirator facepieces.

2. MSA Ultra Twin Respirators are available in the following materials and sizes.

Material Description

Hycar

Size: Small, Medium and Large Size is indicated on a tab inside the lens at the bottom of the lens as well as the color of the lens ring.

Small - Gray lens ring Medium – Black lens ring Large – Gold lens ring

Silicone

Size: Small, Medium, and Large Size is indicated on a tab inside the lens at the bottom of the lens as well as the color of the lens ring.

Small – Gray lens ring Medium – Black lens ring Large – Gold lens ring Silicone designation on the black colored MSA Ultra Twin respirator is located above the lens, immediately beneath the MSA logo.

All yellow colored respirators are silicone material

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2.3.3 Respiratory Equipment Repair Requirements

CAUTION

The use of substitute parts or altering the respirators voids National Institute for Occupational Safety and Health (NIOSH) certification.

1. Perform respirator repairs using trained and qualified persons.

2. Repair faulty respirators and inspect all components in accordance with this procedure so that the devices are returned to a like-new condition.

2.3.4 Respirators That Cannot Be Repaired

1. Respirator should be removed from Respiratory Issuance Tracking System (RITS) when it cannot be repaired.

2. Disassemble MSA Ultra Twin Respirators that cannot be repaired for needed reusable parts.

3. Store all needed reusable parts in supply cabinets for future use.

4. Discard all unneeded and unserviceable parts, including facepieces, in the designated waste container.

2.3.5 Inspection of Unopened Expired Respirators

1. Respirators returned to the REF unopened and expired will be disassembled and inspected following all steps outlined in this procedure.

2.3.6 Respirators for Offsite Use

RPPA approval is required to release respirators offsite.

1. Use new respirators only for offsite training, demonstrations, etc.

2. Return these respirators to the REF for cleaning, sanitizing, and processing.

If circumstances require recycled respirators to be used offsite for a similar purpose, then Radiological Protection Department (RPD) shall perform an unrestricted use survey before release.

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3.0 PRECAUTIONS AND LIMITATIONS

3.1 Safety

1. When using hand tools such as a screwdriver, wear a leather or puncture resistant glove on the hand opposite of the hand holding the tool.

2. The use of substitute parts or altering the respirators voids National Institute for Occupational Safety and Health (NIOSH) certification. Approved spare parts from the manufacturer of the respirator being repaired must be used to maintain NIOSH certification of respirators.

3. Do not use compressed air for cleaning purposes except where reduced to 30 pounds per square inch or less and appropriate personal protection equipment (PPE) is used. Never use compressed air to remove dust or other residue from an employee's body or to blow down an employee’s clothing.

4. Safety glasses with side shields are required when using airblow gun.

5. Additional hazard analysis may be required to ensure that facility/job specific hazards are identified and that the appropriate actions are taken to eliminate/mitigate the identified hazard(s).

6. Use of safety glasses with side shields is required when using airblow gun.

7. A hazard analysis determination was performed on this task (INF-28827).

4.0 PREREQUISITES

1. OBTAIN OSR 4-510 to document information.

5.0 PERFORMANCE

5.1 Respirator

1. INSPECT AND EXAMINE facepiece for water spots, makeup and dirt.

2. WIPE off any water spots, makeup or light dirt from facepiece using a damp cloth with water.

3. DRY damp areas with a lint free dry cloth.

4. IF any respirators have excessive makeup or heavy dirt, THEN

RETURN respirators to the laundry facility for rewashing.

Instructions for the Inspection and Repair of the MSA Ultra Twin Respirator

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5.1 Respirator, (cont.)

5. INSPECT AND EXAMINE the facepiece for the following issues, THEN

PROCEED to appropriate section of procedure for further instruction as needed:

missing or illegible respirator barcode (alpha numeric identifier and barcode) cracks, tears, holes, or distortion inflexibility cracked or badly scratched lens incorrectly mounted lens cracked or broken filter cartridge receptacles, badly worn threads, or missing gaskets missing, deformed or damaged inhalation valves and proper inhalation valve seat

5.1.1 Barcode

1. IF respirator alpha numeric identifier and barcode is illegible or if the barcode is missing, THEN

REPLACE OR ADD a new barcode tag using the key ring tool to open the key ring.

A. WHEN key ring is in the open position, THEN

REMOVE illegible tag if necessary, AND

SLIDE a new tag onto the ring until secure.

B. ATTACH the key ring to the D-ring on the lower right harness buckle (see Figure 8.1, Page 2.)

C. ADD new barcode to RITS database.

5.1.2 Facepiece

1. IF cracks, tears, holes, distortion or inflexibility are found in the facepiece itself, THEN

A. DISASSEMBLE the facepiece.

B. RETAIN any needed serviceable parts for future use, AND

REMOVE barcode number from RITS database.

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5.1.3 Lens

1. IF cracked or badly scratched lens is found, THEN

A. MARK the lens with masking tape to alert the respirator repair person that the lens needs replacing.

B. PLACE the respirator in the bin labeled “TO BE REPAIRED”, AND

PROCEED to Step 3.

2. IF the lens is found to be incorrectly mounted, THEN

A. MARK the lens with masking tape to alert the respirator repair person that the lens needs realigning.

B. PLACE the respirator into the bin labeled “TO BE REPAIRED”, AND

PROCEED to Step 3.

NOTE

Some lens rings require a nut be placed in the lens ring. Some lens rings have a nut built into the lens ring. The nut can be viewed by the metal on one end of the lens ring for those that are built in. (See Figure 8.1, Pages 1 and 2.)

3. IF Lens needs replacing, THEN

A. ENSURE head of screw is opposite of nut when installing screws.

B. REMOVE the screws on both sides of the lens ring, AND

PULL lens ring away from lens.

C. PEEL back the rubber holding the lens in place.

D. WIPE rubber groove with damp cloth or use 30 psig of air to remove dirt in the groove.

E. OBTAIN replacement lens.

F. PLACE lens inside rubber groove, AND

SECURE by running fingers around rubber and lens.

G. OBTAIN the appropriate lens ring for the size respirator being repaired.

H. PLACE lens ring over rubber and lens, AND

SECURE using screws.

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5.1.4 Filter Cartridge Receptacles and Gaskets

1. IF filter cartridge receptacles are cracked, broken, have badly worn threads, OR

IF installing a cartridge receptacle, THEN

A. GRIP around the inhalation valve seat with one hand, while unthreading or threading the cartridge receptacle.

B. REMOVE damaged receptacle, AND

REPLACE.

2. IF the cartridge receptacle gasket is missing, damaged, or Hycar and black in color, THEN

INSTALL silicone gasket, with bevel up, ensuring that the part number is readable, once gasket is in the cartridge receptacle.

5.1.5 Inhalation Valves and Seats

1. IF inhalation valves and seats are missing, deformed, or improper (examples of proper and improper inhalation valve seats are shown in Figure 8.2), THEN

A. REMOVE cartridge receptacle (see Section 5.1.4, Step 1).

B. PUSH inhalation valve seat into respirator.

C. PUSH seat up toward the lens, AND

REMOVE valve and seat.

2. OBTAIN inhalation valve seat.

3. INSPECT valve on removed inhalation valve seat.

A. IF valve is damaged or warped, THEN

OBTAIN replacement valve.

B. IF valve is in good condition, THEN

REMOVE AND REPLACE inhalation valve seat.

4. USE the seat installation tool, if needed, (see Figure 8.3) to open the hole in the respirator left by the removed inhalation valve seat.

5. INSERT replacement inhalation valve seat.

6. REINSTALL cartridge receptacle. (See Step 5.1.4.1)

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5.2 Head Harness

1. INSPECT AND EXAMINE the head harness for:

breaks loss of elasticity broken, malfunctioning, or rust on buckles and attachments excessively worn serrations on the head harness that might permit slippage dry rotting of the rubber

2. IF any defects are found on the head harness, THEN

REPLACE head harness.

5.3 Exhalation Flapper Valve and Exhalation Valve Body

1. REMOVE the exhalation valve cover, AND

INSPECT AND EXAMINE the exhalation flapper valve and exhalation body for the following:

foreign materials, such as detergent residue, dust particles, lint or hair between valve and valve seat cracks, tears, or distortion of the valve improper insertion of the valve body in the facepiece cracks, breaks, or chips in the valve body, particularly on the sealing surface of the seat improper installation of the valve in the exhalation valve body

2. IF foreign materials are found, THEN

REMOVE foreign materials, AND

ENSURE the valve body is properly positioned in the facepiece.

A. IF foreign materials cannot be removed, THEN

REMOVE flapper valve, AND

REPLACE flapper valve.

3. IF crack, tear, or distortion in the flapper valve is discovered, THEN

REMOVE valve, AND

REPLACE flapper valve.

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5.3 Exhalation Flapper Valve and Exhalation Valve Body, (cont.)

4. IF flapper valve is not properly inserted in the exhalation valve body, THEN

PULL exhalation flapper valve tab on the inside of facepiece, AND

ENSURE valve sits flush on exhalation valve body after release of the tab.

5. IF the exhalation valve body has cracks, breaks or chips, THEN

A. REMOVE body by pulling facepiece in one direction and pushing body inward into the facepiece.

B. OBTAIN replacement exhalation valve body.

C. OPEN hole left by removed exhalation valve body using the seat installation tool if needed. (see Figure 8.3)

D. INSERT exhalation valve body.

NOTE

The exhalation valve body is oblong shaped with the oblong body facing the cartridges of the facepiece.

6. IF the exhalation valve body is not properly inserted into the facepiece, THEN

REALIGN using fingers.

5.4 Speaking Diaphragm Housing, O-Ring, Speaking Diaphragm or Retainer Ring

1. INSPECT AND EXAMINE the speaking diaphragm housing for cracks or broken slats on the housing.

2. IF the speaking diaphragm housing is damaged, THEN

A. REMOVE clamp.

B. REMOVE housing from respirator.

C. OBTAIN replacement speaking diaphragm housing.

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5.4 Speaking Diaphragm Housing, O-Ring, Speaking Diaphragm or Retainer Ring, (cont.)

3. IF it is suspected the speaking diaphragm, O-ring, or retainer ring are damaged, THEN

A. DISASSEMBLE speaking diaphragm housing.

B. REMOVE the retainer ring by turning counter clockwise.

C. INSPECT retainer ring for damage.

D. REMOVE speaking diaphragm and O-ring, AND

INSPECT for damage.

4. IF any damage is detected, THEN

A. REPLACE damaged part, AND

REASSEMBLE (see Figure 8.4).

NOTE

Clamp screw should be placed at either the four o’clock or eight o’clock position and not over tightened.

5. INSERT speaking diaphragm housing into facepiece, AND

TIGHTEN the clamp.

5.5 Nosecup

1. INSPECT the nosecup valves and valve seats for damage and ensure the inhalation disc valves and valve seats are in place.

2. IF the nosecup is damaged, THEN

REPLACE parts as necessary.

NOTE

Medium nosecups are used in small respirators. Medium and large nosecups are used in medium and large respirators.

3. INSTALL nosecup by fitting the circular portion of the nosecup onto the retainer ring of the speaking diaphragm housing inside the facepiece.

4. ENSURE the nosecup is centered in the facepiece.

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5.6 Removal of Excess Debris

1. ENSURE the pressure regulator to the airblow gun is set at 30 psig.

2. HOLD airblow gun approximately three inches from the inhalation valve when blowing respirators out, AND

ENSURE that the inhalation valve is not dislodged.

3. BLOW each respirator out using the airblow gun for any:

dust lint detergent hair or other foreign material in facepiece

4. WHEN blowing respirators out, THEN

ENSURE the inhalation valves are in place and are not stuck to the inhalation valve seat.

5. ENSURE the exhalation flapper valve is in place and not stuck to the exhalation valve body.

6. ENSURE cartridge receptacle gaskets are in place.

5.7 Inhalation and Exhalation Valves and Seats and Exhalation Valve Cover

NOTE

Respirators are returned from the Laundry Facility with the exhalation valve covers removed.

CAUTION

Gently probe inhalation valves using care not to push valves off inhalation valve seat.

1. INSPECT exhalation valve cover for damage.

2. IF no damage is found, THEN

INSTALL the exhalation valve cover.

A. IF damage is found, THEN

REPLACE exhalation valve cover.

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5.7 Inhalation and Exhalation Valves and Seats and Exhalation Valve Cover, (cont.)

3. REQUEST peer Respirator Technician to perform the following.

A. VERIFY the inhalation valves are in place and seated flat against inhalation valve seat.

B. VISUALLY VIEW, AND

GENTLY PROBE inhalation valve in each respirator.

C. ENSURE that the proper inhalation valve seat is in place. Proper and improper inhalation valve seats are pictured in Figure 8.2.

4. INSTALL exhalation valve cover over exhalation flapper valve.

5. CHECK tightness of lens screws and speaking diaphragm clamp.

5.8 Cartridges

NOTE

Light rust or discoloring of threads on the cartridge is acceptable. The REF Lead can be contacted for questions on defining light rust.

1. EXAMINE the cartridges for the following types of damage:

dents on bottom rim of cartridge moderate or heavy rust on the bottom or side of the cartridge gray residue or corrosion on the bottom or side of the cartridge

2. ENSURE that the cartridge label is present and legible.

NOTE

Cartridges should not be over tightened.

3. INSTALL the cartridges by holding the cartridge receptacle with one hand while threading the cartridge with the other, AND

HAND TIGHTEN until cartridge engages with the cartridge receptacle gasket.

4. WHEN cartridge engages, THEN

CONTINUE to thread cartridge no more than one quarter turn.

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5.8 Cartridges, (cont.)

5. IF a respirator is for a non-radiological job, THEN

INSTALL new P100 cartridges marked NC on the cartridge; NC identifying cartridge as new.

NOTE

Cartridges marked NC should be disposed of at the job site. Any cartridges returned to the REF marked NC are not to be reused and should be returned to the laundry for proper disposal.

6. INSPECT AND EXAMINE the respirator and cartridge assembly for:

cross-threading in cartridge receptacle correct tightness

7. IF cartridge is cross-threaded or over tightened, THEN

REMOVE cartridge, AND

REINSTALL.

8. IF respirator is equipped with P-100, P-100 marked N/C, GME P-100 and Mersorb P-100 cartridges, THEN

MOVE respirator to the testing area to await leakage testing on the TSI Respirator Leak Tester per Manual 4Q1.7, Procedure 215, Operation of TSI Filter Tester 8127 and TSI 8119 Respirator Leak Tester.

5.9 Post-Performance Activities

1. DISPOSE of unusable/damaged/illegible parts in designated container.

2. RECORD the number of respirators inspected/repaired or found to be defective daily on OSR 4-510.

3. FORWARD completed OSR 4-510 forms to the REF Lead for filing.

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6.0 REFERENCES

Hazard Analysis INF-28827

1Q, Quality Assurance, QAP 15-1, Control of Nonconforming Items

4Q1.7, Respiratory Equipment Procedures, Procedure 215, Operation of TSI Filter Tester 8127 and TSI 8119 Respirator Leak Tester

OSR 4-510, Respiratory Equipment Record and QA

7.0 RECORDS

Records generated as a result of implementing this procedure are maintained in accordance with Manual 1B, Procedure 3.31, Records Management.

OSR 4-510, Respiratory Equipment Record and QA

8.0 ATTACHMENTS

Figure 8.1 Examples of Respirator Lens Rings and D-Ring for Barcode

Figure 8.2 Examples of Proper and Improper Inhalation Valve Seats

Figure 8.3 Photo of the Seat Installation Tool

Figure 8.4 Assembly/Parts Diagram

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FIGURE 8.1

Examples of Respirator Lens Rings and D-Ring for Barcode

D-Ring Respirator with nut inserted

D-Ring Respirator without visible nut

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FIGURE 8.1

Examples of Respirator Lens Rings and D-Ring for Barcode

Respirator lens ring with built-in nut. The screw is inserted from other side of lens ring.

D-Ring for Barcode Attachment

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FIGURE 8.2

Examples of Proper and Improper Inhalation Valve Seats

Examples Proper (Good) Inhalation Valve Seats (Note the ribs on each)

Improper (Bad) Inhalation Valve Seat (Note that inside of seat is smooth, no ribs are visible)

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FIGURE 8.3

Photo of the Seat Installation Tool

Instructions for the Inspection and Repair of the MSA Ultra Twin Respirator

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FIGURE 8.4

Assembly/Parts Diagram

A4802E_FILE_00012300