4Q1.7-307.pdf

Manual: 4Q1.7 Procedure: 307

Revision: 11 PLASTIC HOOD ASSEMBLY Effective Date: 06/28/2016

Type-Class: Tech-Ref Page: 1 of 12

1.0 INTRODUCTION

1.1 Purpose

To provide instructions for assembling National Institute for Occupational Safety and Health (NIOSH) approved air-supplied plastic hoods 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 hoods in the REF by the 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(s) may be utilized in the performance this procedure:

• OSR 4-510, Respiratory Equipment Record and Quality Assurance (QA) form

• OSR 4-979, Plastic Hood Certification Form

2.0 GENERAL INFORMATION

2.1 Definitions and Abbreviations

H-100 - Part number for 100-foot high-pressure breathing air hose for plastic hood with disconnect

L-25 - Part number for 25-foot low-pressure breathing air hose for plastic hood with disconnect

LP-25 - Part number for hood/hose assembly for plastic hoods without disconnect with 25’ low pressure hose.

HP-25 - Part number for hood/hose assembly for plastic hoods without disconnect with 25-foot high pressure hose.

HP-50 - Part number for hood/hose assembly for plastic hoods without disconnect with 50-foot high pressure hose

HP-75 - Part number for hood/hose assembly for plastic hoods without disconnect with 75-foot high pressure hose

HP-100 - Part number for hood/hose assembly for plastic hoods without disconnect with 100-foot high pressure hose

PHAR-D - Part number for Plastic Hood Airline Respirator with Disconnect

Plastic Hood Assembly Revision: 11

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2.2 Responsibilities

1. The REF Lead is responsible for:

• Evaluating OSR 4-510 to determine if significant defective items are reported and notifying the Respiratory Protection Program Administrator (RPPA) and Cognizant Quality Function (CQF) via e-mail.

• Determining if issuance of a Nonconformance Report (NCR) is required and necessary when significant defective items are found and reported.

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

2. REF Personnel are responsible for:

• Inspecting 100% of hoods and hoses, prior to assembly, for proper materials, workmanship, and testing noise levels once assembled. This inspection includes checking for the presence of the plenum, the hanging loop, the Tyvek collar, two elastic straps and the inlet tube and port.

• Performing work outlined in this procedure.

• Ensuring quality of work as specified in Manual 4Q1.7, Procedure 104, Respiratory Equipment Facility Quality Verification

• The individual who assembles the air-supplied plastic hood shall initial the center of the helmet. The individual who tests the air-supplied plastic hood shall initial the hanging loop of the helmet.

• Completely assembling the hood they are working on prior to leaving the work area except in an emergency (i.e., evacuation, fire, etc.).

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

2.3 Information

1. Breathing air hose used on low pressure breathing air systems with manifold pressure of 25 to 30 pounds per square inch gauge (psig) must have a silver or gray plug (male connector). This hose is available in one length, 25-foot length. Low pressure breathing air systems are not equipped with a restricting orifice; part number HP-7-64.

2. Breathing air hose used on high pressure breathing air systems with manifold pressure of 100 to 120 psig must have a black plug (male connector). This hose is available in four lengths: 25-foot, 50-foot, 75-foot and 100-foot. High pressure breathing air systems are equipped with a restricting orifice; part number HP-7-64.

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2.3.1 REF Lot Number and Plastic Hood Part Numbers

1. The REF lot number shall be created as follows:

A. Last two numbers of the year

B. Julian day of the year

C. The sequential number of the assembled plastic hood for the days lot

D. The lot number and part number shall be recorded with large lettering, approximately one inch or larger

Example: 99331001

HP-25

Example: 99 331 001 HP-25 Year Julian

Day First Hood Assembled

Part Number

This example is November 27, 1999, first hood assembled with high pressure (HP) 25-foot hose.

1) When assembling plastic hoods without quick disconnect the part number for the hood/hose assembly used on the low pressure (LP) breathing air systems (BAS) is LP-25, while the ones for the high pressure systems are HP-25, HP-50, HP-75, and HP-100.

2) When assembling plastic hoods with quick disconnect, a “D” shall be written in front of the REF lot number. The plastic hood part number for plastic hoods with quick disconnect is

PHAR-D.

3.0 PRECAUTIONS AND LIMITATIONS

3.1 Safety

1. All tools shall be inspected prior to use for obvious defects, good condition and safe for use.

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

3. 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).

4. The noise level in the hood should not exceed 80 decibels (dBA).

5. Proper lifting techniques are outlined in Manual 8Q, Procedure 12, General Site Safety Requirements

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3.1 Safety, (cont.)

6. As new-type or specialty tools are determined to be used in the process, evaluate need to review Manual 8Q, Procedure 117, Hand and Portable Power Tools, as well as manufacturer guidelines.

4.0 PREREQUISITES

None

5.0 PERFORMANCE

NOTE

DO NOT substitute parts. Only NIOSH approved parts shall be used. Use of parts other than NIOSH approved voids the air supplied plastic hood certification.

5.1 Plastic Hoods With and Without Quick-Disconnect Breathing Air Hoses

5.1.1 Assembling Plastic Hoods With and Without Quick-Disconnect Breathing Air Hoses

1. STAGE the necessary materials.

A. OBTAIN hoods and hoses from warehouse.

B. OBTAIN plastic hood from shipping container, AND

PLACE on workbench.

2. RECORD plastic hood shipping container lot number on OSR 4-979.

3. RECORD breathing air hose container lot number on OSR 4-979.

4. CREATE REF lot number per Section 2.3.1, AND

RECORD on OSR 4-979.

5. RECORD REF lot number on top of the plastic hood plenum.

6. RECORD appropriate part number for hood being assembled on the plastic hood plenum.

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5.1.1 Assembling Plastic Hoods With and Without Quick-Disconnect Breathing Air Hoses, (cont.)

7. INSPECT the hood for:

• presence of a plenum

• presence of the hanging loop

• presence of the Tyvek elastic collar

• presence of two (2) elastic straps

• presence of hose inlet sleeve and hose guide

• rips

• tears

• other defects

8. OBTAIN AND INSPECT proper breathing air hose for plastic hood being assembled.

9. INSERT breathing air hose end with Tygon tubing attached through:

• hood inlet sleeve

• the hose guide

• the plenum circle clamp (double ear)

10. SLIP Tygon tubing onto plenum nipple.

11. SEAT the Tygon tubing on plenum nipple by placing one hand on the outside top of hood above nipple, while pushing Tygon tubing onto the nipple.

12. ORIENT clamp ears to sides of hood plenum.

13. CLAMP Tygon tubing to nipple using the plenum circle clamp.

14. TAPE inlet sleeve end to breathing air hose with pressure sensitive tape.

15. IF defects are found, THEN

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

B. REMOVE the defective component (hose or hood).

C. NOTE the defective condition on the component.

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5.1.1 Assembling Plastic Hoods With and Without Quick-Disconnect Breathing Air Hoses, (cont.)

Step 15, (cont.)

D. REPLACE the defective component.

1) IF the hose is replaced with a hose that has a different lot number, THEN

a) RECORD the new hose lot number on OSR 4-979 for the replacement.

b) IF the hose lot number is the same, THEN

PROCEED to Section 5.1.2.

2) IF the hood is replaced with a hood that has a different lot number, THEN

a) RECORD the new hood lot number on OSR 4-979 for the replacement.

b) IF the hood lot number is the same, THEN

RECORD the new information on a new line of OSR 4- 979 with a new REF lot number.

5.1.2 Hood QA Verification

PEER INSPECTION HOLD POINT

1. VISUALLY INSPECT 100% of all air-supplied hoods assembled for proper crimping of the hood clamp to the hose.

NOTE

Individual performing peer inspection shall place initials on the hood clamp to the hose.

2. PLACE initials on the hood clamp to the hose.

END PEER INSPECTION HOLD POINT

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5.1.3 Checking the Noise Level of Plastic Hood With and Without Quick-Disconnect Breathing Air Hoses

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 at the end of the day.

2. CHECK the noise level in the hood while the hood is still hanging loose on the test stand by reading the sound level meter (mounted on the test stand).

• The noise level should not exceed 80 dBA

3. IF the noise level exceeds 80 dBA, THEN

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

B. REMOVE the defective component (hose or hood).

C. NOTE the defective condition on the component.

D. SEGREGATE defective component in appropriate waste container.

E. REPLACE the defective component.

1) IF lot number is different for the replacement component that was noted on OSR 4-979 for the replacement, THEN

RECORD the new lot number.

F. RELABEL the hood with new REF lot number.

G. REPEAT Steps 5.1.1.6 through 5.1.1.14.

5.1.4 Setup for Inspecting/Testing Plastic Hoods without Quick-Disconnect Breathing Air Hoses

1. PLACE plastic hood on test stand.

2. CONNECT breathing air hose to air manifold.

3. SET manifold pressure.

• 30 psig for low pressure system hoods, OR

• 120 psig with restricting orifice for high-pressure system hoods.

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5.1.5 Setup for Inspecting/Testing Plastic Hoods with Quick-Disconnect Breathing Air Hoses

1. PLACE the 25-foot breathing air hose (part no. H-25) on test-stand arm.

2. CONNECT the male nipple of the breathing air hose to the breathing air manifold.

3. PLACE the plastic hood on test stand.

4. CONNECT the male nipple of the breathing air hose pigtail to the quick disconnect on the breathing air hose (part no. H-25).

5. SET manifold pressure to 120 psig.

5.1.6 Inspecting/Testing Plastic Hoods With and Without Quick-Disconnect Breathing Air Hoses

1. VERIFY the pressure gauge on the manifold is within its calibration period.

2. IF it is not within its calibration period, THEN

NOTIFY the REF Lead.

3. ENSURE manifold is equipped with restricting orifice when testing high pressure hoods.

4. OPEN valve on the air manifold.

CAUTION

When examining the hood, allow enough air to escape so the seams are not ripped or stressed.

5. CHECK the integrity of the assembled plastic hood while the plastic hood is still on the test stand and by grasping the bottom of the hood and holding it closed.

• EXAMINE the hood as it inflates, especially at the seams

• EXAMINE for tears

• EXAMINE for splits

• EXAMINE for other defects

6. IF defects are found, THEN

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

B. REMOVE the defective component (hose or hood).

C. NOTE the defective condition on the component.

D. SEGREGATE defective component in appropriate waste container.

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5.1.6 Inspecting/Testing Plastic Hoods With and Without Quick-Disconnect Breathing Air Hoses, (cont.)

Step 6, (cont.)

E. REPLACE the defective component.

1) IF lot number is different for the replacement component that was noted on OSR 4-979 for the replacement, THEN

RECORD the new lot number.

F. RELABEL the hood with new REF lot number.

G. REPEAT Steps 5.1.1.6 through 5.1.1.13.

7. CLOSE valve on the air manifold.

8. DISCONNECT breathing air hose from manifold or H-25 breathing air hose when testing hoods with quick disconnect.

5.1.7 Packaging Assembled Plastic Hoods without Quick-Disconnect Breathing Air Hoses

1. PERFORM the following prior to packing the air-supplied plastic hoods:

• Quality Assurance check in accordance with Manual 4Q1.7, Procedure 104

• Airflow Testing in accordance with Procedure Manual 4Q1.7, Procedure 108, Air Flow Testing on High and Low Pressure Plastic Hood Airline Respirators.

2. IF alternate packaging quantities or methods are needed, THEN

REQUEST approval by the REF Lead.

3. PLACE assembled hoods in shipping container for delivery to site facilities.

4. ENSURE each shipping container contains the following assembled and tested plastic hoods:

• (10) LP-25

• (10) HP-25

• (5) HP-50

• (4) HP-75

• (4) HP-100

5. AFFIX an orange NIOSH label to the box, AND

LABEL the box with the quantity, hose length, and pressure (LP or HP) (i.e., 10–25' HP, 4–75' HP).

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5.1.8 Packaging Assembled Plastic Hoods with Quick-Disconnect Breathing Air Hoses

1. IF alternate packaging quantities or methods are needed, THEN

REQUEST approval by the REF Lead.

2. PLACE ten assembled and tested hoods in shipping container for delivery to site facilities, OR

PLACE five assembled and tested hoods with the appropriate length hose attached in shipping container per the facility request.

3. AFFIX a white NIOSH label to the box, AND

A. LABEL the box with the quantity, hose length, and pressure if applicable.

B. IF only hoods, THEN

LABEL the box "10 pigtails".

5.2 Post Performance Activities

1. TOTAL rejects, AND

RECORD on OSR 4-510.

2. FORWARD completed OSR 4-510 forms REF Lead for evaluation and filing.

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6.0 REFERENCES

Hazard Analysis INF-20018

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

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

4Q1.7, Procedure 108, Air Flow Testing on High and Low Pressure Plastic Hood Airline Respirators

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

8Q, Employee Safety, Procedure 12, General Site Safety Requirements

8Q, Procedure 117, Hand and Portable Power Tools

OSR 4-510, Respiratory Equipment Record and QA Form

OSR 4-979, Plastic Hood Certification Form

7.0 RECORDS

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

8.0 ATTACHMENTS

Appendix 8.1 Orifice Assembly Photograph

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APPENDIX 8.1

Orifice Assembly Photograph