Approvals: 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-CCER-SOP-0616 Revision: 0.0 Date: 7 April 2014

STANDARD OPERATING PROCEDURE (SOP) FOR HUMAN-SUBJECT WORK RATE (Vo2) 

DETERMINATION FOR PERFORMANCE AND CAPACITY TESTING OF CLOSED-CIRCUIT 

ESCAPE RESPIRATORS (CCERs)

1. PURPOSE

This procedure provides guidance for performing the method to establish the VO2 of a human 

subject for subsequent use in treadmill tests with human subjects of Closed-Circuit Escape 

Respirators (CCER) submitted for Approval, Extension of Approval, or examined during 

Certified Product Audits, meet the minimum certification standards set forth in Section 

84.304(a)(4) and 84.305(a)(3) of Subpart O−Closed Circuit Escape Respirators updated 

requirements to 42 CFR, Part 84, Volume 60, Number 110, June 8, 1995 as published in Federal 

Register / Vol. 77, No. 46 / Thursday, March 8, 2012 / Rules and Regulations pp. 14168-14197.

2. GENERAL

This standard procedure describes measuring VO2 of a human subject on a treadmill, adjusting 

treadmill conditions of speed and inclination so that measured VO2 corresponds to the appropriate 

value required for either the capacity or performance test for Closed-Circuit Escape Respirators in 

sufficient detail such that a person knowledgeable in the appropriate technical field can select 

equipment with the necessary resolution, conduct the determination.

3. EQUIPMENT AND MATERIALS

3.1. Gas analyzers with resolution of 0.1% gas concentration, and range of 0-10% CO2, and 0-

100% O2

3.2. Pressure transducer with resolution of 1millimeter H2O, range from -400 to +400 mm 

H2O with a digital readout.

3.3. Wet and dry-bulb thermometers with resolution of 0.1°C, range 0-100°C

3.4. The equipment necessary to perform measurement and calibration is as follows:

3.4.1. One B-D Yale one liter syringe or equivalent

3.4.2. Doric Series 400A Standard Resolution Digital Temperature indicator or 

equivalent.
Procedure No. TEB-CCER-SOP-0616 Revision: 0.0 Date: 7 April 2014 Page 2 of 5

3.4.3. Data recording and display device consisting of a strip chart recorder and/or 

digital display and data recording software package developed for the metabolic 

monitoring cart and treadmill system or equivalent.

3.4.4. Bench-top electric timer with digital display, calibrated to 100ths (0.01) of a 

minute (Precision Scientific co.) or equivalent.

3.4.5. Digital timer calibrated to 100ths (0.01) of a minute to hand carry or equivalent.

3.4.6. AEI Technologies Carbon Dioxide Analyzer Model CD-3A with a range of 0.00-

15.00%, and resolution of 0.01% or equivalent. A Beckman LB-2 may be used as 

an alternate for NIOSH testing.

3.4.7. AEI Technologies Oxygen Analyzer Model S3-A/I with a range of 0.00%-

100.0%, and a resolution of 0.01% or equivalent. A Beckman Medical Gas 

Analyzer – OM-11 may be used as an alternate for NIOSH testing.

3.4.8. Model 18-49B Horizontal Treadmill, 0-6 MPH, Quinton Instruments, or 

equivalent.

3.4.9. Metabolic cart containing a sampling system that has a relatively large volume 

(ca. 4L) into which the exhaled air is collected and from which the sample for the 

gas analyzers is removed. See picture below.

4. PROCEDURE REQUIREMENTS AND CONDITIONS

4.1. Test subjects must meet requirements of the NIOSH Human Subject Review Board 

(HSRB) approved Protocol. Refer to “Protocol for tests with human subjects of closedcircuit breathing apparatus in certification, quality assurance, and development” HSRB 
Procedure No. TEB-CCER-SOP-0616 Revision: 0.0 Date: 7 April 2014 Page 3 of 5

12-NPPTL-04 for the proper consent form and complete details on the use of human test 

subjects in respirator certification testing.

4.2. Prior to beginning any testing, all measuring equipment and instruments to be used must 

have been calibrated using a method traceable to the National Institute of Standards and 

Technology (NIST) in accordance with the manufacturer's calibration procedure and 

schedule.

4.3. Normal laboratory safety practices must be observed. These include safety precautions 

given in the current NIOSH-Pittsburgh Health and Safety Manual, Job Hazard Analysis 

(JHA), work instruction documents and test equipment manufacturer recommended 

practices.

4.4. Any laboratory using this procedure to supply certification test data to NPPTL will be 

subject to the provisions of the NPPTL 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 NPPTL.)

4.5. Refer to “Protocol for tests with human subjects of closed-circuit breathing apparatus in 

certification, quality assurance, and development” HSRB 12-NPPTL-04 for the consent 

form and complete details on the use of human test subjects in respirator certification 

testing.

4.6. Procedures will be conducted at the following ambient conditions:

4.6.1. Ambient temperatures of 23oC ± 3oC; and

4.6.2. Atmospheric pressures of 735 mm Hg ± 15 mm Hg.

5. PROCEDURES

5.1. The gas analyzers should be calibrated using certified calibration gas with O2 at 80.0 % 

and CO2 at 8.0% and N2 at 12%. 

5.2. Calibrate pneumotachometer on the metabolic cart using 1-L syringe.

5.3. Put assembled T-valve and head harness on human subject and connect exhalation hose 

to metabolic cart.

5.4. Use VO2 prediction equations for weight of human subject to determine initial speed and 

grade of treadmill.

5.4.1. For capacity tests the VO2 should correspond to that in Table 1 below.

5.4.2. For performance tests the VO2 should correspond to those in Table 2 below.

5.5. Have test subject straddle treadmill belt.
Procedure No. TEB-CCER-SOP-0616 Revision: 0.0 Date: 7 April 2014 Page 4 of 5

5.5.1. Have test subject start treadmill belt. 

5.5.2. Ensure that test subject knows which button stops belt. 

5.6. Adjust speed and/or grade at preference of human subject to attain target VO2. 

5.7. When VO2 target is attained, also note VCO2 and Ve from metabolic cart and manually 

determine RF. 

5.8. Have test subject stop treadmill after completion of data collection. 

Table 1: Capacity Test Requirements 

Capacity

Rating

Capacity

(L)

.

V

O2 

(L/min)

.

V

CO2

(L/min)

.

V

e 

(L/min)

RF (Breaths/min)

Cap 1 20 ≤ L ≤ 59 2.50 2.50 55 22

Cap 2 60 ≤ L ≤ 79 2.00 1.80 44 20

Cap 3 L ≥ 80 1.35 1.15 30 18

.

V

O2 = volume of oxygen consumed/min; 

.

V

CO2 = volume of carbon dioxide produced/min 

.

V

e = ventilation rate; RF = respiratory frequency 

Table 2: Performance Test Requirements 

Work-Rate

Test Sequence

Duration

per cycle

.

V

O2

(L/min)

.

V

CO2

(L/min)

.

V

e

(L/min)

RF

(breaths/min)

1. Peak 5 min. 3.00 3.20 65.0 25

2. High 15 min. 2.00 1.80 44.0 20

3. Low 10 min. 0.50 0.40 20.0 12

.

V

O2 = volume of oxygen consumed/min; 

.

V

CO2 = volume of carbon dioxide produced/min 

.

V

e = ventilation rate; RF = respiratory frequency 

6. PASS/FAIL CRITERIA 

None 

7. RECORDS AND TEST SHEETS 

7.1. Record test subject identity, VO2 target attained and the corresponding treadmill speed 

and inclination. 

7.2. Also record VCO2, Ve and RF. 

8. ATTACHMENTS 

None 
Procedure No. TEB-CCER-SOP-0616 Revision: 0.0 Date: 7 April 2014 Page 5 of 5

Revision History

Revision Date Reason for Revision

00 18 August 2011 Initial Record

1.0 29 December 2011 Administrative changes – Document number changed

2.0 09 April 2012 Administrative changes were made to include information from the 

release of the proposed rule.

Former document number - STP-00001-PSDB-0010

0.0 7 April 2014 New document number to reflect numbering in the approval library, 

normalization of format. List of equipment required (section 3) has 

been updated to reflect those currently employed. Current HSRB 

requirements are highlighted in section 4. Accessibility 

enhancements affected. No changes to procedure from historical 

document.