training on environmental products kuwait 2011.ppt
TRANSCRIPT
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Europe
Fume control
systems
20th Nov 2011 AgendaTraining on Environmental products @ Kuwait
09.15 hrs Lincolns contribution to green concept SK
09.30 hrs What is Industrial/welding fume David/SK
09.40 hrs particles/components in the fume David/SK
09.50 hrs Effects of welding Fume David/SK
10.10 hrs Health hazards due to weld fume David/SK
10.20 hrs International standards/requirements David/SKtowards the weld fume
10.30 hrs Fume Control methods & techniques David/SK
10.45 hrs Fume control/removal solutions from Lincoln David/SK
11.00 hrs Demonstartion on the fume control systems David/SK
David (tech expert) from Lincoln Netherlands/ SK Senthil Kumar from Lincoln Dubai
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A study on
Welding Fume
&Its effects
20th Nov2011
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Fume is a cloud
of small
particles
suspended in agas
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What is fume ?
Welding and
cutting fume isformed when a
metal is heated
above its boiling
point, evaporates
and condenses
into very fine solid
particles
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Process conditions
Heat (400C to 12,000C in the arc)
Welding fumes
Consumable electrode (electrode coating) Shielding gases
Fluxes
Base metal Paint or surface coatings
Ultraviolet light leading to photochemical
conversions
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Influencing
factors
Harmful
substancesgasesfumesparticlesvapours
Process
Method
Process-parameter
Basic
material
Additives
Consuma-
bles
Surface-condition
Construction
metalnon-metal/metalnon-metal
metal
wirecover/fillingpowderflux
pollutantscoatings
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Fume control
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Particles & components inthe fume
90 % of the fumes originates from the consumables
The fume contains oxides of the welding consumableand metal being used.
Stick welding processes will produce
fluorides metallic silicates
fluorides fumes.
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Fume control
systems
Particles & components inthe fume
MIG welding processes will produce
Iron oxides
oxides from additives like manganese
SS welding process will produce
Chromium and Nickel oxides
iron oxides also
Metal working fluids ( anti spatter, oils and rust inhibitors)
Coatings like zinc coating or lead primers
RESULT: a mix of gases and particles
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GASESNON TOXIC
PARTICLESTOXIC TOXICIRRITATING
Argon
Helium
Nitrogen
Hydrogen
Carbondioxide
Protective gases Nitrous gases
Ozon
Carbonmonoxides
Hydrogenfluorides
Gases caused by
heating of surface
treatments
Chromium VI-
oxidesCalcium-chromates
Zinc-chromates
Beryllium-oxides
Copper-smoke
Vanadium-oxides
Lead
Cobalt-smoke
Welding fume
(total)
Ferric-oxides
Zinc-oxides
Aluminium-oxides
Mangenese
smoke
Fluorides
Gases cannot be filtered:ventilation is the solution
Particles can be filtered:recirculate or controlled extractionto outside
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Fume control
systems
Particles & components inthe fume
Toxic gases Nitrous gases
Carbon monoxides
Hydrogen fluorides
Toxic Particles Chromium VI oxides
Zinc chromates
Calcium chromates
Copper/cobalt smoke
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Like everything health risk is linked to exposure
Threshold Limit Value (TLV) orMaximumAllowable Concentration (MAC)
Permissible Exposure Limit (PEL)
Ceiling values
Exposure Time Weight Average (TWA) averageconcentration over a working period of 8 hour.
Expressed in mg/m3 in the breathing zone of the welder
General Welding Fume is MAC/TLV of 1-5 mg/m3 basedon TWA 8 with no ceiling limit. Limit depending on eachcountrys legislation.
Components can be lower Chromium VI TLV 0,05 mg/m3,manganese Ceiling is 5 mg/m3
Risk is related to
exposure
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Limit values at the
work station
Dose
Depending on the concentration of harmful
substances
Determination MAC value (max. acceptable concentration;
limit value)
MAC value
average value over 1 working day or 1 shift
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MAC valuesSubstance MAC valuemg/m3
General 3.5
Aluminium oxide (Al2O3 ) 3.5
Lead (Pb) 0,1
Cadmium (Cd) 0,05
Chromium (Cr) 0,5
Chromium IV (Cr(IV)) 0,05
Ferric oxide (Fe2O3) 3.5
Carbon dioxide (CO2) 5,000
Copper (Ca) 0,1
Nickel (Ni) 0,5
Ozone (O3) 0,2
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And related to the fume particle size Respirable fraction PM 2,5
can reach the lungs < 2,5 micrometer of particle size
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What is the
particle size of
welding fume
welding fume
DANGER ZONE
soldering fume
oil fume/mist
airborne dust
virus colour pigment pollen
bacteria hairs
tobacco smoke coal dust
carbon black cement dust
resin fumes milled flour
0 0,01 m 0,1 m 1 m 10 m 100 m(0,1 mm)
visible by electron microscope visible by microscope visible by eye
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Particle size
Danger zone
Particle sizes < 0,1 m are breathed in
Particle sizes between 0,1 and 5 m
remain in the lungs
Particles sizes > 5 m:
filtered by the nose
non-aerosol
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Dimensions
hair dust bacteriumfume
particle
Size Of the Fume particle
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Fume control
systemsEffects of weld fume
Short termEye, ear, nose throat and chest irritation
Metal fever
Nausea
Pneumonitia (inflammation of lung)
- Suffocation
Long term illness
- Chronic asthmaSiderosis
Bronchitis
Neurologic complications
Lung cancer
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How much
welding fume is
produced?
Is mentioned on material safety data sheet
Indication of conversion in percentage of weight
Stick welding 1,5-3% Mig/Mag welding solid wire 0,3-1%
Flux cored wire 3-4 %
Tig
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What
concentration can
be expected ?
0 5 10 15 20 25 30 35 40 45
filled rod/gas steel
Flux cored wire
MIG ALU
MIG stainless
MIG/ MAG steel
MMA stainless
MMA steel
PLASMA stainless
TIG stainless
AUT. cutting steel
GAUGING steel
PLASMA cuttingstainless
TWA level
195
welding fume concentration [ mg/m3 ]
The concentrations measured in mg/m3 of the various weldingprocesses withoutusing welding fume extraction equipment
Source : TNO the
Netherlands
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Basic rules while considering Fume extraction
systems : Filtration and recirculation if welding normal steel
Filtration and exhaust if possible, in case of stainless steel
Extraction at source if possible
Industrial ventilation with personal protection if extraction at source
is not possible
Background concentration MAC = 1-5 mg/m3 (depending on
country)
Tendency to 1 mg/m3 (= health value)
No visible fume layer is max 1,5 mg/m3 !!
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The conclusion is
that
Nearly each welding
process requires protectivemeasurements.
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If you dont Have the fume extraction,
then you may encounter: Health Risk to welder and other persons in Area
Higher Welding Cost by lower arc time % (e.g. due toillness)
Higher energy cost by more ventilation
Effect on machines (more cleaning, maintenance andmachine defects)
Unfiltered ventilation is bad for environment
Image of company (towards employees, customers,unions)
Not having
welding fume
extraction means:
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Advantages in having Fume extractionsystems:
Normal Arc Time about 25%
Total welding cost:84% labour, 13% consumable, 3% investment
2% more Arc Time is 6,5% decrease in total welding cost50% more investment is 1,5% increase in total welding cost
Result: decrease of welding cost of 5%
Thus investment in Welding FumeExtraction
is a Healthy Investment
Welding fume
extraction -
a healthy
investment
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Thus investment inWelding Fume Extraction
is a Healthy Investment
Welding fume
extraction -
a healthy
investment
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Fume control
systemsHow to measure weld fume
The guideline includes the following steps:
1. Pre-Air sampling inspection
2. Preparation of facility
3. Collection and analysis of samples4. Air Sampling Protocol Recommendations
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Fume control
systemsInternational standards
ISO is not specific enough for welding fume.
ISO 9001 is about a general quality system.
ISO 14001 is about an environmental quality system.
Short history of welding fume extraction regulations.1) Started in (Northern) Europe in 1970s because of protection of
workers and cold climate/energy savings by recirculation
2) USA followed Europe quickly. Recent years USA has become verystrict especialy on component level, Manganese, CrVI.
3) Eastern Europe is adapting quickly to rest of Europe.
4) Asia, e.g. China, India starting with regulations now, especially bigmultinational already have systems in place.
5) Tendency not to only look at the welder but to create a generalhealthy environment for all people in workshop
6) Over time tendency of MAC/TLV value from 10 mg/m3 to 1
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Fume control
systemsFume control methods & techniques
- Operator Technique, Welding Consumables, Design,
& Processes
- Source extraction- Personal protection equipments
- Local Extraction using hood
- General filtration- Combination of techniques
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Fume control
systemsFume control solutions from Lincoln
- Good welding techniques
- Portable extractors
- Mobile extraction- Push pull system
- Dilutors
- Modular Hood Extractors- Centralized multi arm extractors