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Health hazards due to weld fume International standards/requirements towards the weld fume
Fume Control methods & techniques Fume control/removal solutions from Lincoln Demonstartion on the fume control systems
David/SK David/SK
David/SK David/SK David/SK
David (tech expert) from Lincoln Netherlands/ SK Senthil Kumar from Lincoln Dubai
What is fume ?
Welding and cutting fume is formed when a metal is heated above its boiling point, evaporates and condenses into very fine solid particles
Process conditions
Influencing factors
Process
Construction
Method
Surfacecondition
pollutants coatings
Harmful substances
gases fumes particles vapours
Processparameter
Consumables
wire cover/filling powder flux
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Metal working fluids ( anti spatter, oils and rust inhibitors) Coatings like zinc coating or lead primers RESULT: a mix of gases and particles
GASES
NON TOXIC TOXIC
PARTICLES
IRRITATING TOXIC
Protective gases
Argon Helium Nitrogen Hydrogen Carbondioxide
Nitrous gases Ozon Carbonmonoxides Hydrogenfluorides Gases caused by heating of surface treatments
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Toxic gases
Nitrous gases Carbon monoxides Hydrogen fluorides
Toxic Particles
Chromium VI oxides Zinc chromates Calcium chromates Copper/cobalt smoke
Like everything health risk is linked to exposure Threshold Limit Value (TLV) or Maximum Allowable Concentration (MAC)
Permissible Exposure Limit (PEL) Ceiling values
Exposure Time Weight Average (TWA) average concentration 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 based on TWA 8 with no ceiling limit. Limit depending on each countrys legislation. Components can be lower Chromium VI TLV 0,05 mg/m3, manganese Ceiling is 5 mg/m3
Dose
Determination
MAC value (max. acceptable concentration; limit value)
MAC value
average value over 1 working day or 1 shift
Substance
General Aluminium oxide (Al2O3 ) Lead (Pb) Cadmium (Cd) Chromium (Cr) Chromium IV (Cr(IV)) Ferric oxide (Fe2O3) Carbon dioxide (CO2) Copper (Ca) Nickel (Ni) Ozone (O3)
MAC values
Respirable fraction 2,5 And related toPM the fume particle size can reach the lungs
< 2,5 micrometer of particle size
DANGER ZONE
welding fume soldering fume oil fume/mist airborne dust virus colour pigment bacteria tobacco smoke carbon black resin fumes coal dust cement dust milled flour pollen hairs
0,01 m
0,1 m
1 m
10 m
visible by microscope
visible by eye
Dimensions
fume particle
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Effects of weld fume Short term Eye, ear, nose throat and chest irritation Metal fever Nausea Pneumonitia (inflammation of lung) - Suffocation
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 <0,2%
The concentrations measured in mg/m3 of the various welding processes without using welding fume extraction equipment
TWA level
filled rod/ gas steel Flux cored wire MIG ALU MIG stainless MIG/ MAG steel MMA stainless MMA steel PLASMA stainless TIG stainless
195
10
15
20
25
30
35
40
45
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 to illness) Higher energy cost by more ventilation Effect on machines (more cleaning, maintenance and machine defects) Unfiltered ventilation is bad for environment Image of company (towards employees, customers, unions)
Thus investment in
Welding Fume Extraction is a Healthy Investment
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4.
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International standards
ISO is not specific enough for welding fume.
1)
2) 3)
Started in (Northern) Europe in 1970s because of protection of workers and cold climate/energy savings by recirculation
USA followed Europe quickly. Recent years USA has become very strict especialy on component level, Manganese, CrVI. Eastern Europe is adapting quickly to rest of Europe.
4)
5) 6)
Asia, e.g. China, India starting with regulations now, especially big multinational already have systems in place.
Tendency not to only look at the welder but to create a general healthy environment for all people in workshop Over time tendency of MAC/TLV value from 10 mg/m3 to 1
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- Operator
- Combination of techniques
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