Training on Environmental products Kuwait 2011.ppt

7/29/2019 Training on Environmental products Kuwait 2011.ppt

1/29

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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Europe

Fume control

systems

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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Europe

Fume control

systems


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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Europe

Fume control

systems


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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Europe

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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Europe

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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Europe

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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Europe

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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Europe

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

Training on Environmental products Kuwait 2011.ppt

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