4Q1.7-302.pdf

Manual: 4Q1.7 Procedure: 302 Revision: 17

PLASTIC SUIT AND WELDER'S JACKET ASSEMBLY Effective Date: 01/02/2018 Type-Class: Tech-Ref Page: 1 of 12

1.0 INTRODUCTION

1.1 Purpose

To provide instructions for assembling air-supplied plastic suits and welder’s jackets in the Respiratory Equipment Facility (REF) for use in site facilities.

1.2 Scope

This procedure applies to the assembling and testing of air-supplied plastic suits and welder’s jackets by REF personnel who are authorized to perform work outlined in this procedure.

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

The following data/round sheet 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

cfm – cubic feet per minute dBA - decibel (A weighted) psig - pounds per square inch gauge

2.2 Responsibilities

1. The Respiratory Equipment Facility (REF) Lead is responsible for:

Evaluating OSR 4-510 to determine if significant defective items are reported

Determining if quality threshold limits have been exceeded

Notifying the Cognizant Quality Function (CQF) and Respirator Protection Program Administrator (RPPA)

Initiating and responding to NCRs per Manual 1Q, Procedure 15-1, Control of Nonconforming Items.

2. REF Personnel are responsible for:

Performing work outlined in this procedure

Ensuring Quality Assurance testing is completed as specified in Manual 4Q1.7, Procedure 104, Respiratory Equipment Facility Quality Verification.

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2.2 Responsibilities, (cont.)

3. The Cognizant Quality Function (CQF) is responsible for:

Providing Quality Assurance guidance for the Respiratory Protection Program

Determining if issuance of a Nonconformance Report (NCR) is required.

4. The Cognizant Technical Function (CTF) is responsible for providing technical guidance for the Respiratory Protection Program.

3.0 PRECAUTIONS AND LIMITATIONS

3.1 Safety

1. A hazard analysis has been performed on this task (INF-20044).

2. 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).

3. Tools shall be safe for use and maintained in good condition. Inspection for obvious defects shall be performed prior to use.

4. Review manufacturer guidelines and department specific guidance as needed for new-type tools and specialty tools per Manual 8Q, Procedure 117, Hand and Power Tools.

5. An approved safety knife (box cutters) shall be used to open shipping containers

6. Cut resistant gloves (Ansell HyFlex 11-511) must be worn on the hand opposite of the hand holding the safety knife or box cutters.

7. Cover or protect sharp edges as applicable.

8. Review and use proper lifting techniques outlined in Manual 8Q, Procedure 12, General Site Safety Requirements.

9. Maintain hoses on hose reels to eliminate tripping hazards.

4.0 PREREQUISITES

4.1 Planning and Coordination

1. COMPLETE qualification training as specified in the Job Performance Standard or approved equal prior to performing this procedure.

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5.0 PERFORMANCE

5.1 Opening Shipping Containers

5.1.1 Opening Plastic Suit Top and Pant Shipping Container

1. REMOVE plastic suit tops and pants from the shipping container.

2. INSPECT plastic suit helmet viewing areas for clarity.

3. IF area is not clear, THEN

A. RECORD as a deficiency to be totaled for the day on OSR 4-510.

B. SEGREGATE defective items in appropriate container.

C. REPORT any unusual defect to the REF Lead.

4. PLACE plastic suit tops and pants on the workbench.

5.1.2 Opening Welder’s Jackets Shipping Container

1. REMOVE welder’s jacket from shipping container.

2. PLACE the welder’s jacket on the work bench with the visor of the helmet facing up.

3. INSPECT viewing lens for visible defects (e.g., hairline cracks, etc.).

4. IF cracks are found, THEN

A. RECORD as a deficiency to be totaled for the day on OSR 4-510.

B. SEGREGATE defective items in appropriate container.

C. REPORT any unusual defect to the REF Lead.

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5.2 Assembly and Inspection of Plastic Suit Tops/Welder’s Jackets and Pants

NOTE

1. There are five different types of plastic suits:

6-Mil plastic suits (available in S, L, and XL) 6-Mil plastic suits with 13 inch helmet for use with a hardhat (available in L only and special order) 12-Mil plastic suits (available in S, L, Tween, and XL) 12-Mil plastic suits with 13 inch helmet for use with a hardhat (available in L only) Welder’s jacket with 12-Mil pants (available in L only)

2. The individual who assembles the air-supplied plastic suit shall initial the center of each helmet using a permanent marker.

1. EXAMINE plastic suit tops/welder’s jackets and pants, especially at seams for:

tears splits other defects

2. EXAMINE the hanging loop of the suit top.

IF the hanging loop separates with no tear, split or integrity damage to the suit, THEN

APPLY Pressure Sensitive tape to repair the loop.

3. IF defects are found, THEN

A. RECORD as a deficiency to be totaled for the day on OSR 4-510.

B. IDENTIFY the location and type of defect with masking tape.

C. SEGREGATE defective items in appropriate waste container.

D. REPORT any unusual defects to the REF Lead.

4. OBTAIN air distribution system (ADS) from the shipping container.

5. ENSURE pressure release plug of the ADS is held in place with a washer and centered under an acorn nut.

6. IF defects are found, THEN

A. RECORD as a deficiency to be totaled for the day on OSR 4-510.

B. IDENTIFY the location and type of defect with masking tape.

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5.2 Assembly and Inspection of Plastic Suit Tops/Welder’s Jackets and Pants, (cont.)

Step 6, (cont.)

C. DISPOSE of defective items in appropriate container.

7. ENSURE pressure release plug has no dents, notches or other defects.

8. IF defects are found, THEN

A. RECORD as a deficiency to be totaled for the day on OSR 4-510.

B. IDENTIFY the location and type of defect with masking tape.

C. DISPOSE of defective ADS in appropriate container.

9. RECORD lot number from ADS shipping container on rear of helmet from plastic suit or on the back of welder's helmet with a permanent marker or equivalent.

10. REMOVE 15 inches plus or minus one-inch from suit inlet sleeve.

11. PLACE ADS, with pressure relief plug away from wearer's back, in the plastic suit top/welder’s jacket.

12. INSERT the ADS air supply hose in the following order:

the grommet the hose guide the hood clamp onto the plenum nipple

13. SEAT hose on the plenum nipple by placing one hand on the outside top of the helmet above the plenum nipple while pushing the air supply hose onto the nipple.

14. ORIENT clamp ear to either side or the rear of hood plenum.

15. CLAMP the hose to the plenum nipple with hood clamp.

16. INSERT the air supply end (pigtail) of the ADS through the air hose inlet sleeve (located at back of suit top/welder’s jacket).

17. PULL the air supply hose (pigtail) until the ADS supply plug (CEJN male nipple) exits the inside of the suit inlet sleeve.

18. FOLD AND TAPE to air distribution hose using white pressure sensitive tape.

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5.3 Airflow Testing of Plastic Suits

NOTE

Airflow testing shall be performed per sampling plans in Manual 4Q1.7, Procedure 104.

1. DETERMINE sample size per Manual 4Q1.7, Procedure 104.

2. VERIFY M&TE equipment to be used is within its calibration period.

3. RECORD M&TE equipment number and calibration data from suit airflow test chamber for pressure gauge and Kurz Flow meter on ISF-REF-005, Suit Flow Test Data Sheet.

4. IF calibration is out of date, THEN

CONTACT the REF Lead.

5. IF ADS air supply line is inserted through the hose inlet sleeve, THEN

REMOVE it from the sleeve.

6. FLIP suit jacket back over the suit helmet.

7. PLACE suit jacket and helmet inside the airflow test chamber with the ADS air supply line, plastic suit silencer distributor (PSSD) and legs on the outside of the test chamber.

8. CLOSE the lid, AND

SECURE the clamps.

9. CONNECT the 3/8 inch x 150 foot breathing air hose to the manifold (equipped with the restricting orifice assembly) and suit to be tested.

10. OPEN valve to breathing air manifold and set pressure at 100 psig.

11. OBSERVE airflow reading on the mass flow meter, AND

RECORD airflow reading on ISF-REF-005.

12. IF airflow reading is NOT between 6.0 cfm and 10 cfm, THEN

REJECT suit.

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5.3 Airflow Testing of Plastic Suits, (cont.)

13. VALVE air OFF, AND

REMOVE suit from the airflow test chamber.

14. IF suit airflow reading is between 6.0 and 10.0 scfm, THEN

INSERT ADS air supply line through the hose inlet sleeve.

15. FOLD AND TAPE ADS air supply line to inlet sleeve using white pressure sensitive tape.

16. DETERMINE the tested suit number based on date tested and a three digit number based on order of test, AND

RECORD suit number on rear of suit helmet and ISF-REF-005.

Example

122409001 where 122409 is the date suit tested and 001 is the first suit tested on that date.

17. WHEN all testing is complete, THEN

ENSURE all paperwork is complete and provide to REF Lead for review.

5.4 Inspecting/Testing the Integrity of Assembled Plastic Suit Top/Welder’s Jackets

NOTE

Sections 5.4 and 5.5 may be repeated for all plastic suits to be tested.

1. PLACE assembled plastic suit top/welder’s jacket on the test stand with cuffs of plastic suit top/welder’s jacket pressed onto cuff holders of test stand.

NOTE

The manifold outlet must have a restricting orifice installed when using 3/8-inch ID breathing air hose.

2. CONNECT the ADS air supply plug to the 3/8-inch ID x 50 foot breathing air hose.

3. OPEN valve to breathing air manifold, AND

SET air pressure at 120 psig.

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5.4 Inspecting/Testing the Integrity of Assembled Plastic Suit Top/Welder’s Jackets, (cont.)

4. INSPECT ADS for the following:

leakage at connections plugs in the air distribution system legs

5. IF defects are found, THEN

A. RECORD as a deficiency to be totaled for the day on OSR 4-510.

B. IDENTIFY the location and type of defect with masking tape.

6. CHECK the integrity of the assembled plastic suit top/welder’s jacket while the plastic suit top/welder’s jacket is still on the test stand.

A. GRASP the bottom of the plastic suit top/welder’s jacket.

B. HOLD it closed allowing enough air to escape to avoid bursting or weakening seams.

C. EXAMINE the plastic suit top/welder’s jacket as it inflates, especially at seams for:

tears splits integrity at hanging loop of suit top, with or without Pressure Sensitive tape other defects

7. IF defects are found, THEN

A. RECORD as a deficiency to be totaled for the day on OSR 4-510.

B. IDENTIFY the location and type of defect with masking tape.

8. TROUBLESHOOT OR REPLACE defective component, AND

DISPOSE of defective plastic suit top/welder’s jacket/ADS in appropriate container.

9. REPORT any unusual defects to the REF Lead.

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NOTE

The individual who tests the air-supplied plastic suit shall initial the loop of each helmet.

10. IF NO defects are found, THEN

RECORD initials on the loop of the helmet of the air-supplied plastic suit to indicate that suit has been tested and who performed the testing.

5.5 Checking the Noise Level of Assembled Plastic Suit Top/Welder’s Jackets

NOTE

Sections 5.4 and 5.5 may be repeated for all plastic suits to be tested.

1. RESPONSE CHECK the Sound Level Meters in accordance with Manual 4Q1.7, Procedure 303, Operation of Sound Level Meter prior to beginning this section, AND

PERFORM check at the end of the day.

NOTE

Noise level should be less than 80 dBA when checking noise level in helmet.

2. WHEN assembled plastic suit top/welder’s jacket is hanging loose on test stand, THEN

CHECK the noise level in the plastic suit/welder’s jacket helmet by reading the sound level meter mounted on the test stand.

3. IF the noise level exceeds 80 dBA, THEN

A. REMOVE the ADS.

B. INSTALL a new ADS.

C. REPEAT beginning at Step 5.2.11 through Section 5.5.

4. IF noise levels continues to exceed 80 dBA, THEN

A. RECORD as a deficiency to be totaled for the day on OSR 4-510.

B. DISPOSE of the defective plastic suit top/welder’s jacket in the appropriate container.

5. CLOSE valve on the breathing air manifold, AND

DISCONNECT the air distribution system supply plug from 3/8 inch x 50 foot breathing air hose.

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5.5 Checking the Noise Level of Assembled Plastic Suit Top/Welder’s Jackets, (cont.)

6. IF problems are encountered, THEN

CONTACT the REF Lead.

7. PERFORM the Quality Assurance testing specified in Manual 4Q1.7, Procedure 104.

A. IF results are acceptable, THEN

PROCEED to Section 5.7.

B. IF results are not acceptable, THEN

NOTIFY REF Lead.

5.6 Checking the Integrity of Plastic Suit Pants

NOTE

Defective plastic suits may be shipped to Site Training for “Training Purposes Only.” If shipped for training, mark the defective suit “Training Purpose Only.”

1. CONNECT the 2-1/2 foot air hose to the breathing air manifold.

2. OPEN valve on the breathing air manifold.

3. SET regulator on the air manifold to 30 psig.

4. CLOSE valve on the air manifold.

5. PLACE the waist of plastic suit pants on the 2-1/2 foot hose, AND

HOLD in place.

6. OPEN valve on the air manifold, AND

INFLATE plastic suit pants.

7. KEEP pants on 2-1/2 foot air hose until fully inflated.

8. While pants are inflated, INSPECT pants for the following:

leaks tears holes

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5.6 Checking the Integrity of Plastic Suit Pants, (cont.)

9. IF defects are found, THEN

A. RECORD as a deficiency to be totaled for the day on OSR 4-510.

B. DISPOSE of defective plastic suit pants in appropriate container.

10. CLOSE valve on the breathing air manifold.

11. REMOVE plastic suit pants from 2-1/2 foot air hose.

12. REPEAT Steps 5 through 11 until all pants are tested.

A. IF problems are encountered in Steps 1 through 11 of this section, THEN

CONTACT the REF Lead.

13. PERFORM the Quality Assurance testing specified in Manual 4Q1.7, Procedure 104.

A. IF results are acceptable, THEN

PROCEED to Section 5.7.

B. IF results are not acceptable, THEN

NOTIFY REF Lead.

5.7 Packaging Assembled Plastic Suit/Welder's Jacket and Pants

5.7.1 Packaging Assembled Plastic Suit Top and Pants

1. PLACE the assembled and tested plastic suit top and plastic suit pants into a shipping container for transport to site facilities.

2. LABEL each shipping container with the number of suits, size of suit, and assembly and test date of suit.

3. ENSURE each shipping container contains the same number of plastic suit tops and the same number of plastic suit pants.

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5.7.2 Packaging Assembled Welder's Jacket and Pants

NOTE

Alternate packing quantities or methods may be approved by the REF Lead.

1. PLACE the assembled and tested welder’s jacket and a pair of 12-mil plastic suit pants into a shipping container for transport to site facilities.

2. LABEL each shipping container with the number of suits, size of suit, and assembly and test date of suit.

3. ENSURE each shipping container contains the same number of welder’s jackets and the same number of 12-mil plastic suit pants.

5.8 Post Performance Activities

1. FORWARD completed OSR 4-510 forms to the REF Lead for evaluation and filing.

6.0 REFERENCES

1Q, Procedure 15-1, Control of Nonconforming Items

4Q1.7, Procedure 104, Respiratory Equipment Facility Quality Verification

4Q1.7, Procedure 303, Operation of Sound Level Meter

8Q, Procedure 117, Hand and Power Tools

8Q, Procedure 12, General Site Safety Requirements

Hazard Analysis INF-20044

ISF-REF-005, Suit Flow Test Data Sheet

OSR 4-510, Respiratory Equipment Record and QA

7.0 RECORDS

Records generated as a result of the performance of 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

None

AAA19A_FILE_00012783