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Welding fume extraction

Programme 2

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1. What is welding fume? 2. European directives 3. Strategy

Welding fume 3

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GASES GASES NON NONTOXIC TOXIC

Protective gases Argon Argon Helium Helium Nitrogen Nitrogen Hydrogen Hydrogen Carbondioxide Carbondioxide

PARTICLES PARTICLES TOXIC TOXIC

Nitrous Nitrousgases gases Ozon Ozon Carbonmonoxides Carbonmonoxides Hydrogenfluorides Hydrogenfluorides Gases Gasescaused causedby by heating of surface heating of surface treatments treatments

IRRITATING IRRITATING

TOXIC TOXIC

Chromium ChromiumIVIVWelding fume Welding fume oxides oxides (total) (total) Calcium-chromates Calcium-chromates Ferric-oxides Ferric-oxides Zinc-chromates Zinc-chromates Zinc-oxides Zinc-oxides Beryllium-oxides Beryllium-oxides Aluminium-oxides Aluminium-oxides Copper-smoke Copper-smoke Mangenese Mangenese Vanadium-oxides Vanadium-oxides smoke smoke Lead Lead Fluorides Fluorides Cobalt-smoke Cobalt-smoke

The origin 4

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• 90% comes from the consumables

• • • •

The rest from: Basic material Protective gases Coatings Other Pollutants (oil)

Influencing factors 5

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Process Construction Construction

SurfaceSurfacecondition condition pollutants coatings

Method Method

Harmful substances gases fumes particles vapours

ConsumaConsumables bles wire cover/filling powder flux

ProcessProcessParameter Parameter (Amperage) (Amperage)

Basic Basic material material Additives Additives metal

metal non-metal/metal non-metal

Particle size Danger zone

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• Particle sizes < 0,1 µm are breathed in and out • Particles sizes > 5 µm: – filtered by the nose

• Particle sizes between 0,1 and 5 µm remain in the lungs

Visibility - harmfulness 7

DANGER ZONE

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welding fume soldering fume oil fume/mist airborne dust colour pigment

virus

pollen

bacteria tobacco smoke

coal dust cement dust

carbon black resin fumes

0

0,01 µm

visible by electron microscope

0,1 µm

hairs

milled flour

1 µm

visible by microscope

10 µm

100 µm (0,1 mm)

visible by eye

Harmfulness of particles 8

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bronchi

alveoli

What happens to the welder 9

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• • • •

Fumes / dust welding fumes in general bronchitis stainless steel (chrome / nickel) carcinogenic zinc / cupper / magnesium metal fume fever coatings (lead) blood poisoning

Gases • nitrogen / ozone / coal monoxide

respiration / eyes

2. European directives 10

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• There is not one conclusive European law • Basic rules are: – – – –

Filtration and recirculation if normal steel Filtration and exhaust in case of stainless steel Extraction at source if possible Industrial ventilation with personal protection if extraction at source is not possible – Concentration in breathing zone of welder MAC = 3,5 mg/m3, but preferably lower – Background concentration 1 mg/m3

Conclusion 11

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Each welding process requires protective measurements.

3. Strategy step by step

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Step 1. Reduce amount of fumes, by: *apply different type of welding (pressure vs fusion welding) *using different type of consumables MAG vs flux core wire TIG vs MAG * use clean material that is free from oil, rust or coating

Strategy: step by step 13

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Step 2. Use fume extraction at source and supply fresh air in the workshop. Make sure the welder is using this equipment. Use easy to work with extraction arms. Step 3. Separate personnel from the source by using cabins or curtains Use of a welding robot

Strategy: step by step 14

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Step 4. Use general ventilation in the workshop if nothing else is possible. (MAC < 3,5 mg/m3) Use personal protection of the welder by means of overpressure helmet or masks

Fume extraction solutions 15

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In order of effectiveness: 1. 2. 3.

source extraction use of hoods create general ventilation together with personal protection

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source

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source

source 18

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source 19

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source 20

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source 21

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source

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source

source 24

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source

Extraction Hoods 26

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HFE

hoods 27

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hoods 28

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hoods 29

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hoods 30

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hoods 31

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hoods 32

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General Ventilation + personal protection

general ventilation 34

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general ventilation 35

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general ventilation 36

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general ventilation 37

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