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First Level Second Level Third Level Fourth Level 

National Institute for Occupational Safety and Health 

National Personal Protective Technology Laboratory 

P.O. Box 18070 

Pittsburgh, PA 15236 

Procedure No. TEB-CBRN-STP-0504 Revision: 0.0 Date: 21 November 2006

DETERMINATION OF CBRN ACID GASES (PHOSGENE) SERVICE LIFE TEST, 

TIGHT-FITTING POWERED AIR-PURIFYING RESPIRATORS STANDARD TEST 

PROCEDURE (STP) 

1. PURPOSE

This test establishes the procedure for ensuring that the level of protection provided by the CBRN 

Acid Gases (Phosgene) Service Life Test, Tight-fitting Powered Air-Purifying Respirators 

(PAPR) Standard Test Procedure submitted for Approval, Extension of Approval, or examined 

during Certified Product Audits meet the minimum certification standards set forth in 42 CFR 

Part 84, Subpart G, Section 84.63(a)(c)(d); Volume 60, Number 110, June 8, 1995 and the 

Statement of Standard for Chemical, Biological, Radiological, and Nuclear (CBRN) Powered 

Air-Purifying Respirators(PAPR). 

2. GENERAL

This STP describes the CBRN Acid Gases (Phosgene) Service Life Test, Tight-fitting Powered 

Air-Purifying Respirators (PAPR) Standard Test Procedure in sufficient detail that a person 

knowledgeable in the appropriate technical field can select equipment with the necessary 

resolution, conduct the test, and determine whether or not the product passes the test. 

3. EQUIPMENT AND MATERIAL

3.1. The list of necessary test equipment and materials follows: 

3.1.1. Miller Nelson Research Model 401 Flow-Temperature-Humidity Control System 

or equivalent. This system is an automated system to control the airflow, 

temperature, and humidity of an air supply for an operating system. Laboratory 

air and distilled water are supplied to the unit. The unit output is air of the 

variable volume/flow dependant on the size of unit (10% of max flow to max 

flow in liters per minute (Lpm) ± 2%), and relative humidity (10%–98% ± 3%) 

and temperature (20oC–30o 0

C ± 0.3%). 

3.1.2. EdgeTech Dew Prime II Hygrometer, Model 2000 or equivalent. A microprocessor based programmable chilled mirror dew point hygrometer. The 

hygrometer uses the dew point and ambient temperature to calculate the relative 

humidity. Ambient temperature range is: -50oC to 130oC ± 0.2oC; relative 

humidity is 1% to 95% ± 0.5%. 
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3.1.3. Labview software developed for NIOSH Service Life Testing. 

3.1.4. California Analytical Instruments, Model 1314 Photoacoustic Multigas Monitor 

with UA0979 optical filter or equivalent. This monitor uses photoacoustic 

infrared detection to measure gases that absorb infrared light. A filter is used to 

select the wavelength specific for the gas being detected. Range for phosgene is 

2000 to 0.02 ppm ± 0.002 ppm. Two detectors are used, one for challenge 

concentration and one for downstream concentration. 

3.1.5. Mass Flow Controller, Brooks Instruments, variable flow rate depending on use. 

3.1.6. Read out and Control Electronics, Brooks Instruments, Model 0154. Power 

supply and controller for the Brooks Mass Flow Controller. The flow controllers 

are an integrally mounted control valve module with which stable gas flows can 

be achieved. Various flow rates are used with an accuracy of ± 0.7 % of rate and 

± 0.2 % full scale. 

3.1.7. Dry Test Meter. American Meter Co., model and size depending on air flow rate 

to be measured. Must have NIST traceable calibration certification. 

3.1.8. Certified cylinder of 250 ppm phosgene in nitrogen. 

3.1.9. Kin-Tek 491MB Basic Gas Standards Generator with phosgene permeation tube 

that is certified to NIST standard or equivalent. 

3.1.10. Phosgene cylinder, 1 to 5 % balance nitrogen. 

3.2 Test fixture for mounting canisters. 

3.3 The test chamber consisting of an air tight box with door opening lined with gasket 

material. Two fittings located on the test chamber for the introduction of the test 

concentration and for the exit of the test fixture. This fixture is not commercially 

available 

3.4 Resistance tester equipment as described in standard test procedures RCT-APR-0007. 

3.5 Airflow measurement equipment as described in standard test procedure RCT-APR00012. 

4. TESTING REQUIREMENTS AND CONDITIONS

4.1. For tight-fitting respirators, this test procedure is only valid if the respirator system has 

first completed NIOSH Standard Test Procedure entitled Durability Conditions Process 

For Environmental, Transportation And Rough Handling Conditions On Chemical 

Biological, Radiological and Nuclear (CBRN) Respiratory Protective Devices (RPD) 

Standard Conditioning Procedure (SCP). 
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4.2. Prior to beginning any testing, all measuring equipment to be used must have been 

calibrated in accordance with the manufacturer's calibration procedure and schedule. At 

a minimum, all measuring equipment utilized for this testing must have been calibrated 

within the preceding 12 months using a method traceable to the National Institute of 

Standards and Technology (NIST). 

4.3. Any laboratory using this procedure to supply certification test data to NIOSH will be 

subject to the provisions of the NIOSH Supplier Qualification Program (SQP). This 

program is based on the tenets of ISO/IEC 17025, the NIOSH Manual of Analytical 

Methods and other NIOSH guidelines. An initial complete quality system audit and 

follow on audits are requirements of the program. Additional details of the Program and 

its requirements can be obtained directly from the institute. 

4.4. Precision and accuracy (P&A) must be determined for each instrument in accordance 

with laboratory procedures and NIOSH/NPPTL guidance. Sound practice requires, under 

NIOSH Manual of Analytical Methods, demonstrating a tolerance range of expected data 

performance of a plus or minus 25% of a 95% confidence interval of the stated standard 

requirement. NIOSH/NPPTL P&A tolerance can be higher but not lower. 

4.5. Compressed gas cylinders must meet all applicable Department of Transportation 

requirements for cylinder approval as well as retesting / requalification. 

4.6. Normal laboratory safety practices must be observed. This includes safety precautions 

described in the current NIOSH Pittsburgh Health and Safety Program. 

4.6.1. Safety glasses, lab coats and hard-toe shoes must be worn at all times. 

4.6.2. Workbenches must be maintained free of clutter and non-essential test 

equipment. 

4.6.3. When handling any broken glass laboratory equipment, lab technicians and 

personnel must wear special gloves, which protect against lacerations or 

punctures. 

4.7 Please refer to Material Safety Data Sheets and the NIOSH Health and Safety 

Manual for the proper protection and care in handling, storing, and disposing of the 

chemicals and gases used in this procedure.

5. PROCEDURE 

 Note: Reference Section 3 for equipment, model numbers and manufacturers. For calibration 

purposes use those described in the manufacturer's operation and maintenance manuals. 

5.1. Follow individual instruction manuals for set up and maintenance of equipment used in 

this procedure prior to beginning testing. Malfunctioning equipment must be repaired or 

replaced and properly set up and calibrated before starting all tests. 
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5.2. Calibrate both photoacoustic monitors for phosgene. One monitor is calibrated for the 

challenge concentration of approximately 250 ppm using the calibrated gas cylinder and a 

second monitor is calibrated for the breakthrough concentration of approximately 1.25 

ppm using the Kin-Tek gas generator and phosgene permeation tube. 

5.3. Set up test equipment as shown in Figure 1. The humidity reading controlled by the 

Miller Nelson system and monitored the Dew Point Hygrometer. The sample pickup for 

the hygrometer is place into the air stream via a tee after the Miller Nelson and before the 

introduction point of challenge agent. The thermocouple for the hygrometer is placed in 

the challenge gas stream immediately before the test chamber. 

5.4. Verify the following equipment is on: 

5.4.1. Miller Nelson Unit. 

5.4.2. Air and water supplies. 

5.4.3. Photoacoustic multi-gas monitors. 

5.4.4. NIOSH Service Life Apparatus Controller software program. 

5.5. Establish the correct humidity and temperature as per the test standard in paragraph 6.3. 

5.6 Set the required airflow for the system. Individual canisters will be tested by dividing 

115 Lpm for the system by the number of air purifying elements on the system. See 

worksheet 2 in appendix 8.2. Verify the airflow from the test fixture using the 

appropriate dry test meter. 

5.7 Weigh and record initial weight of the test canister on Test Data Sheet. 

5.8 Take and record initial airflow measurements in accordance with RCT-APR-012. See 

section 84.1152 (b) Title 42, Code of Federal Regulations, Part 84 for minimum airflow 

requirements. 

5.9 Take and record initial inhalation resistances for tight-fitting PAPR in accordance with 

RCT-APR-007. See Sections 84.122, 84.203, 84.1157 Title 42, Code of Federal 

Regulations, Part 84 for breathing resistance requirements. 

5.10 Ensure that the diverter valve in the system is diverting the challenge concentration 

airflow to discharge and not into testing chamber. 

5.11 Mount canister onto test fixture and place in testing chamber. 

5.12 Ensure that the nitrogen gas is ready for immediate flushing of regulator through the 

purge valve. 

5.13 Turn on phosgene cylinder. 
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Procedure No. TEB-CBRN-STP-0504 Revision: 0.0 Date: 21 November 2006 Page 5 of 11 

5.14 Establish the test concentration of approximately 250 ppm phosgene. 

5.15 Once the phosgene concentration has been established, testing may begin. 

5.16 Direct challenge concentration airflow into test chamber. 

5.17 Start timer. Airflow out of the fixture is directed into the breakthrough detector. Monitor 

and record the upstream and downstream temperatures of the air stream throughout 

testing. Record breakthrough values and times. 

5.18 Run test until breakthrough of 1.25 ppm is observed or selected service life time is 

surpassed. Record this data on the test data sheet. 

5.19 Direct challenge concentration airflow out of the test chamber. 

5.20 Weigh and record final weight of the test canister on Test Data Sheet. 

5.21 Take and record final airflow measurements in accordance with RCT-APR-012. See 

section 84.1152 (b) Title 42, Code of Federal Regulations, Part 84 for minimum airflow 

requirements. 

5.22 Take and record final inhalation resistances for tight-fitting PAPR in accordance with 

RCT-APR-007. See Sections 84.122, 84.203, 84.1157 Title 42, Code of Federal 

Regulations, Part 84 for breathing resistance requirements 

5.23 Allow clean air to purge through test chamber for 5 minutes. 

5.24 Repeat steps 5.5 through 5.19 for each test described in section 6.3. 

5.25 When testing is complete turn off phosgene cylinder, purge regulator with dry nitrogen 

for 10-15 minutes. Set temperature and humidity to zero and allow air to pass through the 

system for 15 minutes. 

6. PASS OR FAIL CRITERIA

6.1. The criterion for passing this test is set forth in 42 CFR Part 84, Subpart G, Section 

84.63(a)(c)(d), Subpart I, Section 84.126, Subpart L, Section 84.207, and Subpart KK, 

Section 84.1157; Volume 60, Number 110, June 8, 1995. 

 6.2. This test establishes the standard procedure for ensuring that: 

 84.63 Test requirements; general. 

(a) Each respirator and respirator component shall when tested by the applicant 

and by the Institute, meet the applicable requirements set forth in subparts H 

through L of this part. 
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Procedure No. TEB-CBRN-STP-0504 Revision: 0.0 Date: 21 November 2006 Page 6 of 11 

(c) In addition to the minimum requirements set forth in subparts H through L of 

this part, the Institute reserves the right to require, as a further condition of 

approval, any additional requirements deemed necessary to establish the quality, 

effectiveness, and safety of any respirator used as protection against hazardous 

atmospheres. 

(d) Where it is determined after receipt of an application that additional 

requirements will be required for approval, the Institute will notify the applicant 

in writing of these additional requirements, and necessary examinations, 

inspections, or tests, stating generally the reasons for such requirements, 

examinations, inspections, or tests. 

6.3. Acid Gas (Phosgene) Test for CBRN Canisters 

6.3.1 Inhalation resistance to airflow of system will be taken before and after each test 

6.3.2 Airflow measurements of system must be taken before and after each test. 

6.3.3 Three canisters will be tested at the determined continuous air flow, 25 % ± 2.5 

% relative humidity (RH), 25 o

 C ± 2.5 o C, and 250 ppm phosgene. 

6.3.4 Three canisters will be tested at the determined continuous air flow, 80 % ± 2.5 

% relative humidity (RH), 25 o C ± 2.5 o

 C, and 250 ppm phosgene.

6.3.5 Minimum service life will be 15, 30, 45, 60, 90 or 120 minutes as per 

manufacturer request. End of service life concentration is 1.25 ppm phosgene. 

7. RECORDS AND TEST SHEETS

7.1. All test data will be recorded on the CBRN Acid Gas (Phosgene) Service Life test data 

sheet. 

7.2. All videotapes and photographs of the actual test being performed, or of the tested 

equipment shall be maintained in the task file as part of the permanent record. 

7.3. All equipment failing any portion of this test will be handled as follows: 

7.3.1. If the failure occurs on a new certification application, or extension of approval 

application, send a test report to the TEB Team Leader and prepare the hardware 

for return to the manufacturer. 

7.3.2. If the failure occurs on hardware examined under an Off-the-Shelf Audit the 

hardware will be examined by a technician and the TEB Team Leader for cause. 

All equipment failing any portion of this test may be sent to the manufacturer for 

examination and then returned to NIOSH. However, the hardware tested shall be 

held at the testing laboratory until authorized for release by the Branch Chief, or 

the Branch Chief’s designee, following the standard operating procedures 
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Procedure No. TEB-CBRN-STP-0504 Revision: 0.0 Date: 21 November 2006 Page 7 of 11 

outlined in Procedure for Scheduling, and Processing Post-Certification Product 

Audits, RB-SOP-0005-00. 

8. APPENDIXES

 8.1 Bench Top Set-Up. 

 8.2 Test Data Sheet. 

 8.3 Calculations for determining airflow for testing
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Appendix 8.1: Bench Top Set-Up. 
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Appendix 8.2: Test Data Sheet. 
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Appendix 8.3: Service life testing airflow calculations. 

Tight-fitting PAPR 

___________ Number of filtering elements on a tight-fitting PAPR System. 

115 Lpm airflow 

Airflow for service life test = 115 Lpm / number of filtering elements 

Test Flow 

4 Cartridges 3 Cartridges 2 Cartridges 1 Cartridge 

28.8 Lpm 38.3 Lpm 57.5 Lpm 115 Lpm 
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Revision History 

Revision Date Reason for Revision 

0.0 21 November 2006 Original Issue