Thorough Examination and Test of Local Exhaust Ventilation Systems to Regulation 9 of the COSHH Regulations 2002 (as amended)

Transcription

1 Thorough Examination and Test of Local Exhaust Ventilation Systems to Regulation 9 of the COSHH Regulations 2002 (as amended) Test of LEV Systems Report Ref: LEV Date: 25 th February 2015 Doncasters Blaenavon Forge Side Blaenavon Pontypool NP4 9XG LEV Services Ltd. Vidanta, Lower Henlade, Taunton, Somerset TA3 5LY. Tel: info@levservices.co.uk

2 Contents 1. Introduction 2. Summary 3. LEV Examination Certificates 4. Supporting Information LEV Services Ltd. Vidanta, Lower Henlade, Taunton, Somerset TA3 5LY. Tel:

3 Report Reference No. LEV Introduction Doncasters Blaenavon specialises in the manufacture of forge ring products for Aerospace and Industrial gas turbines at its site in Blaenavon. Local exhaust ventilation (LEV) systems have been installed on various processes to control the release of substances hazardous to health. This examination is part of the Companies COSHH compliance programme and is the main annual examination and test. Regulation 9 of the Control of Substances Hazardous to Health Regulation (COSHH) 2002 (As Amended) stipulates that all LEV systems are to be assessed by a competent person within a prescribed period. The assessments are crucial in ensuring that all systems are operating effectively and efficiently for continued protection of employee health. The purpose of the examination and test is to conform to Health & Safety requirements as set out in Regulation 9 of the COSHH (Control Of Substances Hazardous to Health) Regulations 2002 (as amended) and LEV test guidelines as set out in HSG258. The test date was 25 th February The test Engineer was Alan Bawler of LEV Services Ltd, the competent person was Alan Bawler trained to BOHS P601, Initial Appraisal And Thorough Examination And Testing Of LEV. Strategy A local exhaust ventilation test was carried out for each plant on site and associated health and safety polices were taken into account for each test. Process Conditions At each stage of the examination and test process, attention was paid to ensuring the LEV system was loaded to a typical operating condition before testing was carried out. It must be emphasised that all results and conclusions pertain only to the conditions prevailing on the date of the tests. Records The record of the examination and tests should be kept by the employer for at least five years, it is the employers responsibility to ensure that the records are kept safely. In the event that the examination and tests are either destroyed or lost then a copy can be obtained from LEV Services Ltd. LEV Services Ltd. Vidanta, Lower Henlade, Taunton, Somerset TA3 5LY. Tel: info@levservices.co.uk

4 2. Summary System Ref. System Description Location Comments LEV 003 Billet Grind Saw Shop Satisfactory LEV 004 Grind Booth No.2 Forge Satisfactory LEV 007 Welding Arm Fitters Shop Satisfactory LEV 008 F.P.I Inspection Satisfactory LEV 009 Developer Booth Inspection LEV 010 Acid Clean Inspection Satisfactory LEV 012 Plasma Cutting Large Blades Forge LEV 013 Fume Cupboard Laboratory LEV 014 Tool Grinding Large Rings Machining Satisfactory, see recommendations for actions to further improve the system. Satisfactory LEV 022 Cross Cut Saw Despatch Satisfactory LEV 024 Steel Polishing DMS LEV 031 Rings Etch Line Etch Room Satisfactory LEV 033 LEV 034 LEV 035 Grinding Cutting & Grind Grind & Linish Large Blades Forge Large Blades Forge Large Blades Forge LEV 039 Etch Line Forge LEV 040 Etch Line Forge LEV 041 Nickel Etch Line Forge Satisfactory, see recommendations for actions to further improve the system. Satisfactory, see recommendations for actions to further improve the system. Satisfactory, see recommendations for actions to further improve the system. Satisfactory Satisfactory LEV 046 Linish & Polish DMS Satisfactory LEV 047 Linish & Polish DMS Satisfactory LEV 052 LEV 053 Forge Forge Large Blades Forge Large Blades Forge Satisfactory, see recommendations for actions to further improve the system. Satisfactory, see recommendations for actions to further improve the system. Satisfactory, see recommendations for actions to further improve the system. Satisfactory, see recommendations for actions to further improve the system. Satisfactory LEV 054 Etch Testing Forge Satisfactory LEV 055 LEV 056 LEV 057 LEV 059 LEV 060 Mazak Oil Mist Extraction Mazak Oil Mist Extraction Rotary Blaster Rotary Blaster Weingarton Fume Extract Large Rings Machining Large Rings Machining Large Blades Forge Large Blades Forge Large Blades Forge Satisfactory, see recommendations for actions to further improve the system. Satisfactory Satisfactory Satisfactory Unable to make an Assessment Satisfactory LEV Services Ltd. Vidanta, Lower Henlade, Taunton, Somerset TA3 5LY. Tel:

5 Comments use a traffic light colour code system; Green - satisfactory with no recommendations Yellow - satisfactory with recommendations Red unsatisfactory with recommendations Refer to individual LEV examination certificates for the recommendations to any LEV system. Responsibility With LEV systems / hoods that are deemed unsatisfactory it is the responsibility of the employer to remedy the failures as soon as possible. The certification is only valid for the systems / hoods that are satisfactory and all failures must be retested after remedial works have been completed to give the system / hoods a satisfactory certificate. LEV Services Ltd. Vidanta, Lower Henlade, Taunton, Somerset TA3 5LY. Tel: info@levservices.co.uk

6 3. LEV Examination Certificates LEV Services Ltd. Vidanta, Lower Henlade, Taunton, Somerset TA3 5LY. Tel:

7 Report Reference: LEV LEV Examination & Test Thorough Examination and Test of Local Exhaust Ventilation Systems to Regulation 9 of the COSHH Regulations 2002 (as amended) System Ref: LEV 003 Company Doncasters Blaenavon Forge Side Blaenavon Pontypool NP4 9XG Test Date: 25/02/2015 Tested by: A.Bawler Signature Last Test Date: Next Test Date: System Location: LEV Process / Type: Extractor: 16/01/ /08/2015 Saw Shop Grinding of Billets Climavent LW22 MC No. MC No. Released Substances To Be Controlled Steel containing cobalt, nickel Alumina Oxide Dust a a Mist Fume Vapour Gas Assessment of System The system was found to be SATISFACTORY at controlling the hazardous substances. Extraction Components / Specifications Extractor Manufacturer: Climavent Model: LW22 Serial No: PDI 1635 Fan Manufacturer: Climavent Fan Type: Centrifugal Drive Type: Direct Fan Serial No. Inlet Dia (m): Outlet Dia (m): Fan Airflow Rate. 3700m³/hr Motor Manufacturer: Motor (kw): 4 Prior to fan: Motor (rpm): Primary Filter Manu: N/A Description: Water Arrest System At Inlet: At Outlet: Across Filter: Secondary Filter Manu: Description: Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: a Model: 435/4 Rotating Vane: a Serial No: /910 Hotwire: Calibration Date: None At Inlet: At Outlet: Across Filter: 01/07/2014 Visual (smoke / lamp): a The system was tested under normal working conditions, the operation is conducted outside under a shelter however the prevailing wind can enter the shelter to disturb the dust release pattern. Page 1 of 97 LEV003

8 Plant Photograph / Diagram Discharge direct to atmosphere MD1 TP2 TP1 Extraction unit discharging direct to TP1 TP2 atmosphere Page 2 of 97 LEV003

9 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Capture Distance (m) Qualitative Test Verdict of Examination Description of LEV system & Process A dust extraction unit is used to control the release of dust generated by a large hand held grinding machine, there are two extraction hoods on the machine, one at the wheel hood to capture dust that is released centrifugally from the rotating wheel and a hood that is positioned in the path of the dust release during the grinding of the components. The dust is transferred to the extraction unit by the means of solid and flexible ducting. The extraction unit uses water to arrest the dust where it settles into the extractor sump, the residual air is then discharged direct to atmopshere. LEV System Visual Examination Notes Discharge Termination: Direct from Fan Motor Direction: Correct Cleaning System: None Airflow Indicators: Yes Additional Comments: The system is in good working order. Discharge to: Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: To Atmosphere As new N/A Satisfactory Examination Readings & Results Duct Reading Face Reading Results PASS PASS PASS PASS Main Duct Reading Ref Dimensions Area Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) Summary The extraction system was satisfactory at controlling the release of dust from the grinder the dust is released in the direction of the receptor hood (TP1) and extracted to the extraction unit. The hood TP1 has adequate face velocity to capture the dust released from the rotating grinding wheel. Recommendations None. Page 3 of 97 LEV003

10 Report Reference: LEV LEV Examination & Test Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 004 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 16/01/2014 Next Test Date: 25/08/2015 System Location: No.2 Forge LEV Process / Type: Grinding Booth MC No. Extractor: Qty 2 Climavent LW22 MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Steel containing cobalt, nickel Alumina Oxide Assessment of System The system was found to be SATISFACTORY at controlling the hazardous substances. a a Extraction Components / Specifications Extractor Manufacturer: Climavent Model: LW22 Serial No: Fan Manufacturer: Climavent Fan Type: Centrifugal Drive Type: Direct Fan Serial No. Inlet Dia (m): Outlet Dia (m): Fan Airflow Rate. 3700m³/hr Motor Manufacturer: Motor (kw): 4 Motor (rpm): Prior to fan: Primary Filter Manu: N/A Description: Water Arrest System At Inlet: At Outlet: Across Filter: Secondary Filter Manu: None Description: At Inlet: At Outlet: Across Filter: Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: a Model: 435/4 Rotating Vane: a Serial No: /910 Hotwire: Calibration Date: 01/07/2014 Visual (smoke / lamp): a The system was tested under normal working conditions to ensure the released dust is contained by the booth and there is no escape of the dust into the workplace. Page 4 of 97 LEV004

11 Plant Photograph / Diagram Discharge direct to atmosphere TP2 Face reading TP1 TP1 & TP2 Extraction unit discharging direct to atmosphere Page 5 of 97 LEV004

12 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Capture Distance (m) Qualitative Test Verdict of Examination Description of LEV system & Process A shallow booth is used to control the release of grinding dust during a grinding operation, the grinding operation is performed at the face of the booth and the dust is released into the booth. The booth is connected to two dust extraction units which uses water to arrest the dust and the residual air is discharged direct to atmosphere by the use of discharge stacks. LEV System Visual Examination Notes Discharge Termination: Motor Direction: Cleaning System: Airflow Indicators: Straight Duct Correct None Yes Additional Comments: System in good working order, water levels correct. Discharge to: Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: To Atmosphere Good Condition N/A Satisfactory Examination Readings & Results Duct Reading Face Reading Results PASS PASS System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) N/A Summary The system was satisfactory and it is the opinion of the assessor that the released substance is adequately controlled. A smoke test demonstrated good visualisation of the air flow in and around the booth. The grinding must take place within the booth for control to be achieved. Recommendations None Page 6 of 97 LEV004

13 Report Reference: LEV Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 007 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 08/07/2013 Next Test Date: 25/04/2016 System Location: Fitters Shop LEV Process / Type: Welding MC No. Extractor: GEC Fan unit MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Steels Plant Photograph / Diagram a Fan unit discharging direct to atmosphere TP1 TP1 Discharge stack direct to atmosphere Page 7 of 97 LEV007

14 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Distance (m) Qualitative Test Verdict of Examination Description of LEV system & Process An extraction system is used to control the release of fume from general welding operations within the engineering / maintenance department. The system consists of a flexible arm to allow the capture hood to be positioned close to the point of fume release the fume is then transferred to a fan unit and then discharged direct to atmosphere by the use of an accelerator cowl. Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: a Model: 435/4 Rotating Vane: a Serial No: /910 Hotwire: Calibration Date: 01/07/2014 Visual (smoke / lamp): a The system was tested under normal working conditions with a face reading taken at the hood with a capture distance for the safe working distance from the hood. LEV System Visual Examination Notes Discharge Termination: Motor Direction: Cleaning System: Airflow Indicators: Accelerator Cowl Correct None Yes Discharge to: Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: To Atmosphere Additional Comments: The system was found to be in good condition with all components working correctly, the pivoting arm and hood worked as designed and the flexible ducting between the fan unit and the arm was in good condition with no signs of wear or splits. None N/A Satisfactory Examination Readings & Results Duct Reading Face Reading Results PASS PASS System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 949 N/A Page 8 of 97 LEV007

15 Summary The system was satisfactory at controlling the release of welding fume, there was adequate duct transfer and face velocities to ensure adequate control. The minimum capture velocity could be achieved upto 250mm from the face of hood, the hood must be positioned within this distance to effectively control the fume. A smoke test demonstrated good control at the capture distance and that the sealed joints on the discharge side of the fan unit was adequate to prevent escape of fume back into the workplace. Recommendations None Extraction Components / Specifications Extractor Manufacturer: Model: Serial No: Fan Manufacturer: VFR (m3/hr): Motor Manufacturer: GEC GEC Fan Type: Inlet Dia (m): Motor (kw): Centrifugal Drive Type: Outlet Dia (m): Motor (rpm): Direct Prior to fan: After Fan: Across fan: Primary Filter Manu: None Description: None At Inlet: Secondary Filter Manu: None At Outlet: Description: None At Inlet: At Outlet: Across Filter: Across Filter: Page 9 of 97 LEV007

16 Report Reference: LEV Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 008 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 08/07/2013 Next Test Date: 25/04/2016 System Location: Inspection Department LEV Process / Type: Fluorescent Dye Penetrant Inspection Booth MC No. Extractor: RHF Fans MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Dye Penetrant a a Plant Photograph / Diagram Fan unit discharging direct to atmosphere TP1 Page 10 of 97 LEV008

17 TP1 (Tested with curtain open 800mm) Page 11 of 97 LEV008

18 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Distance (m) Qualitative Test Verdict of Examination Description of LEV system & Process An extraction system is used to control the release of vapours from a fluorescent dye penetrant spraying operation. A booth is used to spray the dye onto components, the booth has curtains on the two sides and front to enclose the spray area. The spray is electrostatically charged which prevents over spray. The operator stands on the outside of the booth with the curtains partially open to allow use of the spray gun. The vapour is extracted through filter panels at the rear of the booth to remove the mist / particulate and the residual air is discharged direct to atmosphere. Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: Model: 435/4 Rotating Vane: a Serial No: /910 Hotwire: Calibration Date: 01/07/2014 Visual (smoke / lamp): a The system was tested under normal working conditions, as it is a vapour that is being controlled a 0.5m/s face velocity needs to be achieved to prevent escape of the vapour back into the workplace. The two side curtains were closed as would be in normal conditions and the front curtain closed until the minimum face velocity could be achieved, the resulting opening in the curtain would then be the maximum opening the curtain can be opened to during spraying. LEV System Visual Examination Notes Discharge Termination: Motor Direction: Cleaning System: Airflow Indicators: Coolie Hat Correct None Yes Discharge to: Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: To Atmosphere Additional Comments: The system was in good working order, the filter panel at the rear of the booth were in good condition and the curtains around the booth were in good condition with no tears or missing sections that would create an opening to reduce the face velocity at the spraying area. A visual examination of the discharge stack was not possible due to the location. Good N/A Satisfactory Examination Readings & Results Duct Reading Face Reading Results PASS PASS System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 7989 N/A Page 12 of 97 LEV008

19 Summary The system was satisfactory at controlling the release of vapours from the dye penetrant spraying operation, the curtain at the front of the booth can be opened to a maximum of 800mm to allow the operator to reach into the booth with the spray nozzle. There was adequate face velocity with the opening at 800mm, during the spraying the side curtains must remain closed to ensure the correct face velocity at the front of the booth is achieved. Recommendations None Extraction Components / Specifications Extractor Manufacturer: Model: BDA610 Serial No: 298/5820/1 Fan Manufacturer: VFR (m3/hr): Motor Manufacturer: RHF Fan Type: Inlet Dia (m): Motor (kw): Axial Drive Type: Outlet Dia (m): Motor (rpm): Belt Prior to fan: -128 After Fan: Across fan: Primary Filter Manu: Generic Description: Glass Fibre panel Filters At Inlet: At Outlet: Across Filter: Secondary Filter Manu: None Description: None At Inlet: At Outlet: Across Filter: Page 13 of 97 LEV008

20 Report Reference: LEV Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 009 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 08/07/2013 Next Test Date: 25/04/2016 System Location: Inspection Department LEV Process / Type: Dye Penetrant Developer MC No. Extractor: RHF Fan Unit MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Developer Powder Plant Photograph / Diagram a Fan Filter box TP1 Page 14 of 97 LEV009

21 TP1 Discharge direct to atmosphere Page 15 of 97 LEV009

22 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Distance (m) Qualitative Test Verdict of Examination Description of LEV system & Process An extraction system is used to control the release of dust from a developer powder spraying operation. A booth is used to spray the developer powder onto components, the booth has an opening at both ends, a solid two section door to allow loading / unloading of components, this is closed during spraying and a curtain front to allow th eoperator to stand at the booth front for the spraying. The spray is electrostatically charged which prevents over spray of the powder reducing any escape to the workplace. The powder is extracted from within the booth by extraction points in the roof of the booth and then discharged direct to atmosphere. Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: Model: 435/4 Rotating Vane: a Serial No: /910 Hotwire: Calibration Date: 01/07/2014 Visual (smoke / lamp): a The system was tested under normal working conditions, as it is a fine dust that is being controlled with no external air turbulance a 0.5m/s face velocity needs to be achieved to prevent escape of the dust back into the workplace. The solid doors were closed as would be in normal conditions and the front curtain closed until the minimum face velocity could be achieved, the resulting opening in the curtain would then be the maximum opening the curtain can be opened to during spraying. LEV System Visual Examination Notes Discharge Termination: Motor Direction: Cleaning System: Airflow Indicators: Grille Correct None Yes Discharge to: Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: To Atmosphere Unknown Additional Comments: The system was in good working order with all components working as designed, the main doors were easy to close to ensure the booth is enclosed, the duct and fan system was in good condition through out. A filter box has been installed since the last test. N/A Satisfactory Examination Readings & Results Duct Reading Face Reading Results PASS PASS System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) N/A N/A N/A N/A Page 16 of 97 LEV009

23 Summary There was adequate face velocity to prevent the escape of dust back into the workplace, a visual examination during the spray operation found there to be no dust escape when conducting a lamp test. The curtain opening should not exceed 1200mm wide to achieve the recommended face velocity. Recommendations Fit magnehelic gauge to monitor the filter condition and to warn when it needs cleaning / replacing. Extraction Components / Specifications Extractor Manufacturer: Model: BDA610 Serial No: 295/5820/1 Fan Manufacturer: VFR (m3/hr): Motor Manufacturer: RHF Unknown Fan Type: Inlet Dia (m): Motor (kw): Axial Drive Type: Outlet Dia (m): Motor (rpm): Belt Prior to fan: -100 After Fan: Across fan: Primary Filter Manu: Unknown Description: G4 filter panels At Inlet: Secondary Filter Manu: None At Outlet: Description: None At Inlet: At Outlet: Across Filter: Across Filter: Page 17 of 97 LEV009

24 Report Reference: LEV Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 010 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 08/07/2013 Next Test Date: 25/04/2016 System Location: Inspection Department LEV Process / Type: Acid Cleaning MC No. Extractor: Nederman N24 Fan Unit MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Hydrochloric Acid, Hydrofluoric Acid a a Plant Photograph / Diagram Fan unit discharging direct to atmosphere TP1 TP1 Page 18 of 97 LEV010

25 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Distance (m) Qualitative Test Verdict of Examination Description of LEV system & Process An extraction system is used to control the release of vapours from an acid cleaning operation. The system consists of a flexible arm to allow the capture hood to be positioned close to the point of fume release the fume is then transferred to a fan unit and then discharged direct to atmosphere by a section of duct with a high velocity discharge termination. Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: Model: 435/4 Rotating Vane: a Serial No: /910 Hotwire: Calibration Date: 01/07/2014 Visual (smoke / lamp): a The system was tested under normal working conditions with a face reading taken at the hood. The process is close to a fire exit door which is in use, this could cause turbulance of the vapour. LEV System Visual Examination Notes Discharge Termination: Motor Direction: Cleaning System: Airflow Indicators: Straight Duct Correct None Yes Discharge to: Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: Additional Comments: The system was in good working order with all components working correctly and in good condition. To Atmosphere None N/A Satisfactory Examination Readings & Results Duct Reading Face Reading Results PASS PASS Summary The system was satisfactory at controlling the release of vapours from the acid cleaning operation. There was adequate face velocity with a capture distance of 250mm from the face of the hood. The operator must ensure that the hood is placed within this distance from the cleaning operation when extracting the vapour and that the fire exit door remains closed to prevent any turbulance of the vapour. Recommendations None Page 19 of 97 LEV010

26 Extraction Components / Specifications Extractor Manufacturer: Model: Serial No: 522 Fan Manufacturer: VFR (m3/hr): Motor Manufacturer: Nederman Nederman Fan Type: Inlet Dia (m): Motor (kw): Centrifugal Drive Type: Outlet Dia (m): Motor (rpm): Direct Prior to fan: After Fan: Across fan: Primary Filter Manu: None Description: None At Inlet: Secondary Filter Manu: None At Outlet: Description: None At Inlet: At Outlet: Across Filter: Across Filter: Page 20 of 97 LEV010

27 Report Reference: LEV Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 012 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 08/07/2013 Next Test Date: 25/04/2016 System Location: Large Blades Forge LEV Process / Type: Plasma Cutting Bench MC No. Extractor: Axial Fan Unit MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Steel containing cobalt, nickel Plant Photograph / Diagram a MD1 TP1 TP2 Discharge direct to atmosphere Page 21 of 97 LEV012

28 TP1 TP2 Fan unit in-line Discharge direct to atmosphere Page 22 of 97 LEV012

29 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Distance (m) Qualitative Test Verdict of Examination Description of LEV system & Process an extraction system is used to control the release of fumes during a plasma cutting operation. A cutting bench with two extraction points is used to capture the fume, it is then transferred to a fan unit before being discharged direct to atmosphere by the use of a discharge stack with a high velocity discharge termination. Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: a Model: 435/4 Rotating Vane: a Serial No: /910 Hotwire: Calibration Date: 01/07/2014 Visual (smoke / lamp): a The system was tested under normal working conditions with a face velocity of 0.5m/s to be achieved to control the released fume. The duct reading for TP1 is calculated by taking the duct reading TP2 from the main duct reading. LEV System Visual Examination Notes Discharge Termination: Motor Direction: Cleaning System: Airflow Indicators: High Velocity Discharge Correct None Yes Discharge to: Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: To Atmosphere Additional Comments: The rear extraction hood and bottom drop out box extraction points were in good condition with no signs of any debris that could lead to partial blockages of the system. The ducting was in good order and has been secured using sealant and fixings to ensure a good seal at the joints. N/A N/A Satisfactory Examination Readings & Results Duct Reading Face Reading Results NA PASS PASS PASS PASS Main Duct Reading Ref Dimensions Area Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 3564 N/A Page 23 of 97 LEV012

30 Summary The system is satisfactory at controlling the fume generated by the plasma cutting operation on the bench, the transfer duct velocity and face velocities met recommended guidelines and the combined face readings from TP1 & TP2 gave a capture distance of 700mm from the face of the rear extraction hood, which extends further out than the depth of the bench. All plasma cutting should be conducted within the bench and over the extracted hole (TP2) to ensure adequate control. Recommendations None Extraction Components / Specifications Extractor Manufacturer: Model: Serial No: Fan Manufacturer: VFR (m3/hr): Motor Manufacturer: Unknown Unknown Fan Type: Inlet Dia (m): Motor (kw): Axial 0.4 Unknown Drive Type: Outlet Dia (m): Motor (rpm): Direct 0.4 Prior to fan: After Fan: Across fan: Primary Filter Manu: None Description: None At Inlet: Secondary Filter Manu: None At Outlet: Description: None At Inlet: At Outlet: Across Filter: Across Filter: Page 24 of 97 LEV012

31 Report Reference: LEV Fume Cupboard Examination & Test Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV to Regulation 9 of the COSHH Regulations 2002 (as amended) 013 Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 08/07/2013 Next Test Date: 25/04/2016 System Location: Fan Airflow Rate. Laboratory Cupboard Manu: Unknown MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Various Chemicals Assessment of System The system was found to be SATISFACTORY at controlling the hazardous substances however, there are actions required to monitor or improve the system. See readings and summary sections. Extraction Components / Specifications Extractor Manufacturer: Model: Serial No: Fan Manufacturer: Durafan Limited Fan Type: Centrifugal Drive Type: Direct Fan Serial No. Inlet Dia (m): Outlet Dia (m): a Motor Manufacturer: Unknown Motor (kw): 0.37 Motor (rpm): 1390 Prior to fan: Primary Filter Manu: None Description: At Inlet: At Outlet: Across Filter: Secondary Filter Manu: None Description: At Inlet: At Outlet: Across Filter: Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: Model: 435/4 Rotating Vane: Serial No: /910 Hotwire: a Calibration Date: 01/07/2014 Visual (smoke / lamp): a Tested under normal working conditions with cupboard loaded as normal. Page 25 of 97 LEV013

32 Plant Photograph / Diagram Discharge direct to atmosphere TP1 Page 26 of 97 LEV013

33 TP1 Fan unit discharging direct to atmosphere Visual indicator for maximum setting at 500mm high Visual indicator for setting at 300 mm high Page 27 of 97 LEV013

34 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Capture Distance (m) Qualitative Test Verdict of Examination Description of LEV system & Process A fume cupboard enclosure is used to control the release of vapours from various chemicals / acids used within the laboratory. The cupboard has a sash door with two opening settings to indicate the maximum opening of the sash door when in use. The cupboard is connected to a fan unit that is located outside by sections of pvc ducting, the vapours are transferred by this duct to the fan and then discharged direct to atmosphere by the use of a discharge stack and a high velocity discharge termination. LEV System Visual Examination Notes Discharge Termination: Motor Direction: Sash Door Operation: Light Operation: Airflow Indicators: Sash Height Alarm: Filter Last Replaced: High Velocity Discharge Correct Satisfactory Satisfactory No No N/A Discharge to: Duct Condition (Visual): Worktop Condition: Rear Baffle: Airflow Indicator Working: Sash Height Alarm Working: Filter Condition (Visual): To Atmosphere Good Satisfactory Satisfactory Additional Comments: Tested at 500mm opening. The anti-vibration mounts on the fan unit are perished and need to be replaced. There are no sash height stops, these should be fitted to prevent use of the cupboard with the sash too high. N/A N/A N/A Examination Readings & Results Sash Operating Height: Min Reading: Max Reading: % Deviation From Mean Readings within 20% 500mm / 29.6 No Duct Reading Face Reading Results PASS PASS Summary There was adequate face velocity with an air flow visualisation demonstrating good containment and no escape into the workplace. The minimum and maximum readings were above 20% of the mean due to containers within the enclosure causing the high and low reading. Recommendations Replace the anti-vibration mounts on the fan unit. Fit sash height stops to prevent use over 500mm opening. Page 28 of 97 LEV013

35 Report Reference: LEV Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 014 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 08/07/2013 Next Test Date: 25/04/2016 System Location: Large Rings Machining LEV Process / Type: Pedestal Grinding (Tools) MC No. Extractor: DCE UMA456 K11 MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Steel Plant Photograph / Diagram a Extraction unit discharging back into the workplace MD3 MD1 MD2 TP3 TP4 Bleed valve (TP5) TP2 TP1 TP4 TP3 TP2 TP1 Page 29 of 97 LEV014

36 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Distance (m) Qualitative Test Verdict of Examination Description of LEV system & Process A dust extraction unit is used to control the release of dust from a hand grinding operation on pedestal grinders. The system is a multipoint system with 4 take offs, one to each grinding head, the system is constructed using galvanised steel and flexible ductwork. The extraction system operates when the grinding wheels are activated, this removes operator error and ensures the control is in place. The extraction unit is fitted with filter bags and has a mechanical shaker which operates when the extractor is stopped. After the particulate is filtered the residual air is then discharged back into the workplace. Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: a Model: 435/4 Rotating Vane: Serial No: /910 Hotwire: a Calibration Date: 01/07/2014 Visual (smoke / lamp): a The system was tested under normal working conditions with all dampers open as set with the volume control dampers at the rear of the grinder hoods. The duct readings of TP2, TP3, TP4 are calculated from the main duct readings. LEV System Visual Examination Notes Discharge Termination: Motor Direction: Cleaning System: Airflow Indicators: Direct from Fan Correct Auto Shaker Yes Discharge to: Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: Back to Workplace Additional Comments: The shaker was not operating each time the extractor was powered down, this needs to be investigated and reapirs made. Good No Satisfactory Examination Readings & Results Duct Reading Face Reading Results PASS PASS NA NA NA PASS PASS Main Duct Reading Ref Dimensions Area Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD MD MD System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) PASS PASS 2073 N/A NA PASS PASS NA Page 30 of 97 LEV014

37 Summary The system was satisfactory at controlling the release of dust from the grinding operation, although the transfer duct velocities were lower than recommended there was no signs of settlement in the duct indicating that the duct velocities achieved are enough to ensure no settlement within the duct. The face velocities were adequate for the control of the dust during grinding, a lamp test demonstrated good control while grinding. The face velocities to TP1 & TP2 could be increased by opening the size of the take off at the rear of the hoods to increase the air volume. Recommendations Investigate intermittant issue with the shaker mechanism / motor. Extraction Components / Specifications Extractor Manufacturer: DCE Model: UMA456 K11 Serial No: Fan Manufacturer: VFR (m3/hr): Motor Manufacturer: DCE Fan Type: Inlet Dia (m): Motor (kw): Centrifugal 7.5 Drive Type: Outlet Dia (m): Motor (rpm): Direct 2860 Prior to fan: After Fan: Across fan: Primary Filter Manu: DCE Description: Polyester Needle felt multi-pocket bag At Inlet: At Outlet: Across Filter: 154 Secondary Filter Manu: None Description: None At Inlet: At Outlet: Across Filter: Page 31 of 97 LEV014

38 Report Reference: LEV Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 022 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 08/07/2013 Next Test Date: 25/04/2016 System Location: Despatch Department LEV Process / Type: Cross Cut Saw MC No. Extractor: DCE UMA153 K5 MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Soft Wood Plant Photograph / Diagram a Extraction unit discharging back into the workplace TP1 TP1 Page 32 of 97 LEV022

39 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Distance (m) Qualitative Test Verdict of Examination Description of LEV system & Process A dust extraction unit is used to control the release of soft wood dust from a cross cut saw, the extractor is connected to a receptor hood at the rear of the saw by the use of galvanised steel ductwork. The saw cuts from the back to the front resulting in the released dust being released in the direction of the receptor hood. The extraction unit is fitted with filter bags and has a mechanical shaker which operates when the extractor is stopped. After the particulate is filtered the residual air is then discharged back into the workplace. The extractor is fitted with an explosive relief panel in the event the dust ignites causing an explosion. Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: a Model: 435/4 Rotating Vane: a Serial No: /910 Hotwire: Calibration Date: 01/07/2014 Visual (smoke / lamp): a The system was tested under normal working conditions with a 1.0m/s capture velocity to ensure that when the dust is directed into the path of the capture zone all dust is controlled adequately. LEV System Visual Examination Notes Discharge Termination: Motor Direction: Cleaning System: Airflow Indicators: Direct from Fan Correct Auto Shaker Yes Discharge to: Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: Additional Comments: The extractor has been moved by 90 degrees to vent the explosion panel away form the wall. The ducting has been increased in size to improve air volumes. Back to Workplace Good Yes Satisfactory Examination Readings & Results Duct Reading Face Reading Results PASS PASS System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 1421 N/A Page 33 of 97 LEV022

40 Summary There was adequate velocities at the hood to control the released dust, a visual examination demonstrated good containment during cutting with little escape to the workplace. The system is deemed satisfactory for use. As this is the first test since the modification this reading will be used as a bench mark for future tests. Recommendations None. Extraction Components / Specifications Extractor Manufacturer: DCE Model: UMA153 K5 Serial No: Fan Manufacturer: VFR (m3/hr): Motor Manufacturer: DCE ABB Fan Type: Inlet Dia (m): Motor (kw): Centrifugal 2.2 Drive Type: Outlet Dia (m): Motor (rpm): Direct 2800 Prior to fan: After Fan: Across fan: Primary Filter Manu: DCE Description: Polyester Needle felt multi-pocket bag At Inlet: At Outlet: Across Filter: 495 Secondary Filter Manu: None Description: None At Inlet: At Outlet: Across Filter: Page 34 of 97 LEV022

41 Report Reference: LEV LEV Examination & Test Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 024 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 16/01/2014 Next Test Date: 25/08/2015 System Location: Fan Airflow Rate. Blade Polishing (DMS) LEV Process / Type: Steel Polishing MC No. Extractor: DISA FMS200-4A MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Steel containing cobalt, nickel Alumina Oxide Assessment of System The system was found to be SATISFACTORY at controlling the hazardous substances however, there are actions required to monitor or improve the system. See readings and summary sections. Extraction Components / Specifications Extractor Manufacturer: Disa Model: FMC200-4A Serial No: 2260 Fan Manufacturer: Disa Fan Type: Centrifugal Drive Type: Direct Fan Serial No. Inlet Dia (m): Outlet Dia (m): a a Motor Manufacturer: Motor (kw): 11 Motor (rpm): Prior to fan: Primary Filter Manu: Disa Description: Cartridge (CA100-66F FM831) At Inlet: At Outlet: Across Filter: 1020 Secondary Filter Manu: None Description: At Inlet: At Outlet: Across Filter: Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: a Model: 435/4 Rotating Vane: a Serial No: /910 Hotwire: Calibration Date: 01/07/2014 Visual (smoke / lamp): a Tested under normal working conditions with all points open (the linisher has ben removed). Page 35 of 97 LEV024

42 Plant Photograph / Diagram TP7 Extraction unit discharging direct to atmosphere TP8 TP6 TP4 TP3 TP5 TP1 TP2 Extraction unit discharging direct TP2 TP1 to atmosphere TP5 TP6 TP7 TP8 Page 36 of 97 LEV024

43 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Capture Distance (m) Qualitative Test Verdict of Examination Description of LEV system & Process A dust extractio unit is used to control the release of dust from various linish and polishing machines. The system is constructed of galvanised steel and flexible ducting leading from a header duct to capture hoods at each abrading station. All extraction hoods are fitted with blast gate dampers to allow the closing of points when not in use or to re-distribute the extraction volume to other machinery. The extractor is fitted with cartridges to filter the dust and the residual air is then discharged direct to atmosphere. The extractor is fitted with a reverse pulse air jet system to clean the cartridges and works off a differential pressure over the cartridges. LEV System Visual Examination Notes Discharge Termination: Motor Direction: Cleaning System: Airflow Indicators: 135 Termination Discharge to: To Atmosphere Correct Reverse Pulse Jet Yes Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: Additional Comments: The galvanised duct had been secured together using self tapping screws which is not a preferred method of construction when dusts are to be controlled. Points TP1, TP2, TP3,TP4 & TP6 are not in use and currently closed off, the system was tested in this set up. The hood on TP5 is in poor condition with part of it missing causing a drop in face capture velocity at the wheel. Good Yes Satisfactory Examination Readings & Results Duct Reading Face Reading Results N/A N/A N/A N/A N/A N/A N/A N/A PASS PASS N/A N/A PASS PASS PASS PASS Main Duct Reading Ref Dimensions Area Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) Page 37 of 97 LEV024

44 Summary The system was satisfactory at controlling the release of dusts from the grinder and linisher, the control at the grinder would be considered minimal due to the poor condition of the hood and as such the hood should be repaired. There was adequate face velocities and duct transfer velocity at the linisher. Although the overall air volume is lower than initial radings this is due to the removal of machines from the system. Recommendations Repair the hood on TP5. Page 38 of 97 LEV024

45 Report Reference: LEV Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 031 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 08/07/2013 Next Test Date: 25/04/2016 System Location: Rings Etch Line LEV Process / Type: Etching MC No. Extractor: Ketville Fan & Scrubber Unit MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Acids including Ferric Chloride, Hydrochloric Acid Plant Photograph / Diagram a TP10 TP9 TP8 TP7 TP6 TP5 TP4 TP3 TP2 TP1 MD1 MD2 Fan unit discharging direct to atmosphere Scrubber unit Page 39 of 97 LEV031

46 Scrubber & fan unit discharging to atmosphere Plant layout TP5 TP4 TP3 TP2 TP1 TP10 TP9 TP8 TP7 TP6 Description of LEV system & Process An extraction system is used to control the release of acid vapours from an etching process. The system has a scubber unit for the cleaning of the fume before a fan unit discharges the residual air direct to atmosphere. The vapour release is controlled by the use of lip extraction points each side of the treatment tanks. Each tank has a lid which remains closed when not in use. Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: a Model: 435/4 Rotating Vane: Serial No: /910 Hotwire: Calibration Date: 01/07/2014 Visual (smoke / lamp): a The system was tested under normal working conditions and tested with 4 tanks in use at any one time with all other tank lids closed to ensure the extracted air volume is directed to the tanks in use. Smoke tests were conducted to ensure adequate control due to depth of tanks. Page 40 of 97 LEV031

47 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Distance (m) Qualitative Test Verdict of Examination LEV System Visual Examination Notes Discharge Termination: Unknown Discharge to: To Atmosphere Motor Direction: Correct Filter Condition (Visual): Unknown Cleaning System: Scrubber Cleaning System Working: Yes Airflow Indicators: Yes Airflow Indicators Working: Satisfactory Additional Comments: The system was in good working order with all components working correctly, all ducting was in good condition with no signs of any leakage at any of the joints which visually looked as though they have been adequately sealed by bolted flanges. The lip extraction points were clear of any debris that could lead to partial blockages. Examination Readings & Results Duct Reading Face Reading Results PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS Main Duct Reading Ref Dimensions Area Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD MD System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) N/A Page 41 of 97 LEV031

48 Summary The system is satisfactory at controlling the release of vapours from the etching process, there was adequate face velocities and although the minimum face velocity could not be achieved across the complete surface of the tanks and there was a big variation in the face velocity at the lips a smoke test demonstrated that the vapours are removed with very little release if any into the workplace. Recommendations None Extraction Components / Specifications Extractor Manufacturer: Fan Manufacturer: VFR (m3/hr): Motor Manufacturer: Ketville Ketville Unknown Model: Fan Type: Inlet Dia (m): Motor (kw): Scrubber Centrifugal Serial No: Drive Type: Outlet Dia (m): Motor (rpm): Belt Prior to fan: Primary Filter Manu: Ketville After Fan: Description: Scrubber Across fan: At Inlet: -668 At Outlet: -902 Across Filter: 234 Secondary Filter Manu: None Description: None At Inlet: At Outlet: Across Filter: Page 42 of 97 LEV031

49 Report Reference: LEV LEV Examination & Test Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 033 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 17/03/2014 Next Test Date: 25/08/2015 System Location: Large Blades Forge LEV Process / Type: Grinding MC No. Extractor: Climavent LW22 MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Titanium Based Alloys Alumina Oxide Assessment of System The system was found to be SATISFACTORY at controlling the hazardous substances. a a Extraction Components / Specifications Extractor Manufacturer: Climavent Model: LW22 Serial No: PDI 0139 Fan Manufacturer: Climavent Fan Type: Centrifugal Drive Type: Direct Fan Serial No. Inlet Dia (m): Outlet Dia (m): Fan Airflow Rate. 3700m³/hr Motor Manufacturer: Motor (kw): 4 Motor (rpm): Prior to fan: Primary Filter Manu: N/A Description: Water Arrest System At Inlet: At Outlet: Across Filter: Secondary Filter Manu: None Description: At Inlet: At Outlet: Across Filter: Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: a Model: 435/4 Rotating Vane: a Serial No: /910 Hotwire: a Calibration Date: 01/07/2014 Visual (smoke / lamp): a The system was stood down and run for test purposes only. All test points open. Page 43 of 97 LEV033

50 Plant Photograph / Diagram Extraction unit discharging direct to atmosphere MD1 TP4 TP3 TP2 TP1 Extraction unit Discharge stack to atmosphere Page 44 of 97 LEV033

51 TP1 TP2 TP3 TP4 Description of LEV system & Process A wet dust extraction unit is used to control the release of metallic dusts from a range of linish and polishing machines. The system consists of a main header duct with drops to the individual machines and final connections to the capture hoods at each process by the use of galvanised ducting. The extraction unit which uses water to arrest the dust and the residual air is discharged direct to atmosphere by a discharge duct exiting the adjacent wall. LEV System Visual Examination Notes Discharge Termination: Motor Direction: Cleaning System: Airflow Indicators: Straight Duct Correct None Yes Discharge to: Filter Condition (Visual): Cleaning System Working: Additional Comments: The capture hoods at each point were clear of any debris allowing clear airflows. Airflow Indicators Working: To Atmosphere Good N/A Satisfactory Page 45 of 97 LEV033

52 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Capture Distance (m) Qualitative Test Verdict of Examination Examination Readings & Results Duct Reading Face Reading Results PASS PASS PASS PASS PASS PASS PASS PASS Main Duct Reading Ref Dimensions (m) Area (m 2 ) Recommended Flow rate (m 3 /h) Pressure (Pa) MD System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) Summary It is the opinion of the assessor that all control points are adequate to control the release of dust, there was good face and duct transfer velocities with no evidence of settlement and overall performance is inline with previous tests. At the grinder test points TP1 & TP2 had adequate face velocity at 75mm from the hood face which is inline with the rest plate of the grinder, duct transfer velocities were also sufficient for transfer of the substance. At the belt linisher good face velocities were achieved along with suffiecient duct transfer velocities for suspension of the substances. Recommendations None. Page 46 of 97 LEV033

53 Report Reference: LEV LEV Examination & Test Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 034 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 17/03/2014 Next Test Date: 25/08/2015 System Location: Large Blades Forge LEV Process / Type: Cutting & Grinding MC No. Extractor: Climavent LW22 MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Titanium Based Alloys Alumina Oxide Assessment of System The system was found to be SATISFACTORY at controlling the hazardous substances. a a Extraction Components / Specifications Extractor Manufacturer: Climavent Model: LW22 Serial No: PDI 0140 Fan Manufacturer: Climavent Fan Type: Centrifugal Drive Type: Direct Fan Serial No. Inlet Dia (m): Outlet Dia (m): Fan Airflow Rate. 3700m³/hr Motor Manufacturer: Motor (kw): 4 Motor (rpm): Prior to fan: Primary Filter Manu: N/A Description: Water Arrest System At Inlet: At Outlet: Across Filter: Secondary Filter Manu: None Description: At Inlet: At Outlet: Across Filter: Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: a Model: 435/4 Rotating Vane: a Serial No: /910 Hotwire: Calibration Date: 01/07/2014 Visual (smoke / lamp): a The system was tested under normal working conditions, for testing of the linisher the saw was closed off. Page 47 of 97 LEV034

54 Plant Photograph / Diagram Extraction unit discharging direct to atmosphere MD1 TP5 TP4 TP3 MD2 TP2 TP1 Extraction unit Discharge stack to atmosphere TP1 TP2 TP3 TP4 TP5 Page 48 of 97 LEV034

55 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Capture Distance (m) Qualitative Test Verdict of Examination Description of LEV system & Process A wet dust extraction unit is used to control the release of metallic dusts from a range of linish and polishing machines. The system consists of a main header duct with drops to the individual machines and final connections to the capture hoods at each process by the use of galvanised ducting. The extraction unit which uses water to arrest the dust and the residual air is discharged direct to atmosphere by a discharge duct exiting the adjacent wall. TP1 - TP4, belt linisher, each belt has an extraction point at the rear of the belt guard and a large receptor hood with drop out box below the linishing area to receive the dust as it is released. The receptor hood also provides some capture to help influence dust that is escaping the receptor area. When using this linisher the damper to the chop saw is closed off to ensure all extraction is at the linisher. TP5, chop saw, this uses a receptor hood at the rear of the saw, during cutting the dust and spraks are discharged into the receptor section of the hood where it is controlled, the saw can be used with the linisher extraction ports open. LEV System Visual Examination Notes Discharge Termination: Motor Direction: Cleaning System: Airflow Indicators: Straight Duct Correct None Yes Discharge to: Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: To Atmosphere Good N/A Satisfactory Additional Comments: None. Examination Readings & Results Duct Reading Face Reading Results PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS Main Duct Reading Ref Dimensions Area Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD MD System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) Page 49 of 97 LEV034

56 Summary The system was adequate at controlling the release of dust from the points TP1, TP3 and TP5, although for maximum performance it is recommended that the damper to TP5 is closed off when the linishers are in use. The main duct transfer velocity for TP1,3 & 4 met recommended guidelines and there was no signs of settlement in the ducting. The face velocity was adequate at the drop out box as the path of the released dust enters the hood / drop out box with little escape until the operator pushes hard on the components forcing the abrading process. The face velocity at TP2 and TP4 was lower than recommended however a dust lamp test did not show any escape of dust at these points and the low duct transfer velocity at TP2 was due to debris over the extraction point at the rear of the belt guard. There was good duct transfer velocity and face velocity at the chop saw, with the cut area being fully enclosed any dust escape is considered minimal and it is the opinion of the assessor that control is achieved. Recommendations None. Page 50 of 97 LEV034

57 Report Reference: LEV LEV Examination & Test Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 035 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 17/03/2014 Next Test Date: 25/08/2015 System Location: Fan Airflow Rate. Large Blades Forge LEV Process / Type: Grinding & Linishing MC No. Extractor: Climavent LW22 MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Titanium Based Alloys Alumina Oxide Assessment of System The system was found to be SATISFACTORY at controlling the hazardous substances however, there are actions required to monitor or improve the system. See readings and summary sections. Extraction Components / Specifications Extractor Manufacturer: Climavent Model: LW22 Serial No: PDI 0124 Fan Manufacturer: Climavent Fan Type: Centrifugal Drive Type: Direct Fan Serial No. Inlet Dia (m): Outlet Dia (m): 3700m³/hr a a Motor Manufacturer: Motor (kw): 4 Motor (rpm): Prior to fan: Primary Filter Manu: N/A Description: Water Arrest System At Inlet: At Outlet: Across Filter: Secondary Filter Manu: None Description: At Inlet: At Outlet: Across Filter: Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: a Model: 435/4 Rotating Vane: a Serial No: /910 Hotwire: Calibration Date: 01/07/2014 Visual (smoke / lamp): a The system was tested under normal working conditions. Page 51 of 97 LEV035

58 Plant Photograph / Diagram Extraction unit discharging direct to atmosphere MD1 MD2 TP1 TP2 TP3 TP4 TP3 MD3 Extraction unit Discharge stack to atmosphere Page 52 of 97 LEV035

59 TP1 TP2 TP3 TP5 TP4 Page 53 of 97 LEV035

60 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Capture Distance (m) Qualitative Test Verdict of Examination Description of LEV system & Process A wet dust extraction unit is used to control the release of metallic dusts from various linishing and grinding machines. Direct from the extractor a duct system extends to the machines which utilise a combination of capture and receptor hoods. The extraction unit which uses water to arrest the dust and the residual air is discharged direct to atmosphere by a discharge duct exiting the adjacent wall. TP1 - a receptor hood is used on a small belt linisher, during linishing the release dust is released into the hood where it is then transferred to the duct system. TP2 & TP3 - receptor hoods are integrated in the wheel guard and are used to receive the dust during grinding, the hood also provides a negative pressure to ensure containment of the dust. TP4 - TP5, belt linisher, each belt has a large receptor hood with drop out box below the linishing area to receive the dust as it is released. The receptor hood also provides some capture to help influence dust that is escaping the receptor area. LEV System Visual Examination Notes Discharge Termination: Motor Direction: Cleaning System: Airflow Indicators: Straight Duct Correct None Yes Discharge to: Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: To Atmosphere Good N/A Satisfactory Additional Comments: The ducting design on this system is not preferred due to the excessive bends and duct length that are used causing pressure drops and a reduction in air flow. There is no damper fitted to allow isolation of the bench mounted equipment TP1 - TP3 to direct full extraction capacity to the linishers. Examination Readings & Results Duct Reading Face Reading Results PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS Main Duct Reading Ref Dimensions Area Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) Page 54 of 97 LEV035

61 Summary There was satisfactory control at each point in the system with adequate duct transfer velocities and face velocities to ensure control. Due to the long length in duct to the linisher TP4 & TP5 it is recommended that when the linisher is in use the other points are closed off for improved control, this requires a damper to be fitted to the bench mounted equipment / grinder. Recommendations The complete layout now needs to be reviewed with focus to move the linisher closer to the dust collector to prevent settlement in the duct system. The duct to the bench mounted grinder should have a damper to allow it to be closed off when the linisher is in use. Page 55 of 97 LEV035

62 Report Reference: LEV Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 039 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 08/07/2013 Next Test Date: 25/04/2016 System Location: Forge LEV Process / Type: Etch Line MC No. Extractor: Unknown Fan Unit MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Various Acids Plant Photograph / Diagram a Fan unit discharging direct to atmosphere MD1 TP1 TP2 TP3 TP4 TP5 TP6 TP7 Page 56 of 97 LEV039

63 Fan unit Discharge stack to atmosphere Treatment line Description of LEV system & Process An extraction system is used to control the release of acid vapours from an etching process. The system has a fan unit that extracts the vapours by the use of lip extraction hoods and discharges the vapour direct to atmosphere. The vapour release is controlled by the use of lip extraction points each side of the treatment tanks. The treatment line has strip curtains to prevent air turbulence when the doors are opened and the line is semi automatic preventing the operator from having to work closely to the tanks. Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: a Model: 435/4 Rotating Vane: a Serial No: /910 Hotwire: Calibration Date: 01/07/2014 Visual (smoke / lamp): a The system was tested under normal working conditions, a main duct reading was taken to ensure it compares to past readings and due to the restricted access to the treatment tanks a visual examination was taken along with a smoke test to ensure the released vapours are controlled. Page 57 of 97 LEV039

64 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Distance (m) Qualitative Test Verdict of Examination LEV System Visual Examination Notes Discharge Termination: High Velocity Discharge Discharge to: To Atmosphere Motor Direction: Correct Filter Condition (Visual): N/A Cleaning System: None Cleaning System Working: N/A Airflow Indicators: Yes Airflow Indicators Working: Satisfactory Additional Comments: Heavy deposits of fume settlement on lip extraction hoods TP3, TP4 & TP5. Examination Readings & Results Duct Reading Face Reading Results x PASS PASS x x PASS PASS PASS PASS x PASS PASS x PASS PASS x PASS PASS PASS PASS Main Duct Reading Ref Dimensions Area Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) Page 58 of 97 LEV039

65 Summary The system is satisfactory at controlling the release of vapours from the treatment tanks, there was adequate main duct velocity and duct velocities to each extraction hood to ensure transfer of the vapour within the duct system. Recommendations Ensure the lip extraction hoods are kept clear of build up. Extraction Components / Specifications Extractor Manufacturer: Model: Serial No: Fan Manufacturer: VFR (m3/hr): Motor Manufacturer: Unknown Unknown Fan Type: Inlet Dia (m): Motor (kw): Centrifugal 0.63 Unknown Drive Type: Outlet Dia (m): Motor (rpm): Belt 0.63 Unknown Prior to fan: After Fan: Across fan: Primary Filter Manu: None Description: None At Inlet: Secondary Filter Manu: None At Outlet: Description: None At Inlet: At Outlet: Across Filter: Across Filter: Page 59 of 97 LEV039

66 Report Reference: LEV Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 040 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 08/07/2013 Next Test Date: 25/04/2016 System Location: Forge LEV Process / Type: Barrel Etch Line MC No. Extractor: Unknown Scrubber & Fan Unit MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Various Acids Plant Photograph / Diagram a Scrubber unit Fan unit discharging direct to atmosphere TP1 TP2 TP3 TP4 TP5 TP6 TP7 TP8 TP9 TP10 MD1 Page 60 of 97 LEV040

67 Scrubber unit and discharge to atmosphere Treatment line Description of LEV system & Process An extraction system is used to control the release of acid vapours from an etching process. The system has a scubber unit for the cleaning of the fume before a fan unit discharges the residual air direct to atmosphere. The vapour release is controlled by the use of lip extraction points each side of the treatment tanks. The treatment line has strip curtains to prevent air turbulence when the doors are opened and the line is semi automatic preventing the operator from having to work closely to the tanks. Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: a Model: 435/4 Rotating Vane: Serial No: /910 Hotwire: Calibration Date: 01/07/2014 Visual (smoke / lamp): a The system was tested under normal working conditions, doors closed no external air turbulence. LEV System Visual Examination Notes Discharge Termination: Motor Direction: Cleaning System: Airflow Indicators: High Velocity Discharge Correct Scrubber Yes Discharge to: Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: To Atmosphere Unknown Additional Comments: The air flow indicator showed a large drop in performance since the last test however, due to the operator not being directly exposed to the vapour release as it is a semi-automated system the control was still adequate even if minimal. Yes Satisfactory Page 61 of 97 LEV040

68 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Distance (m) Qualitative Test Verdict of Examination Examination Readings & Results Duct Reading Face Reading Results PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS Main Duct Reading Ref Dimensions Area Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD1 0.5 x System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) Summary There was minimal control of the vapours released from the process with a visual examination showing some signs of possible vapour escape when using a smoke tube. The static pressure in the main duct along with the duct transfer velocity has taken a huge drop which indicates an issue with the scrubber unit (possible blockage?). Given that the barrel line is separated from the operator with no direct interaction it is the opinion of the assessor that there is reasonable control however the drop in performance needs to be investigated to return the system to its original performance levels. PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS Recommendations Investigate the drop in performance, possible location of the issue is anywhere between the fan and the duct entering the building. Extraction Components / Specifications Extractor Manufacturer: Model: Serial No: Fan Manufacturer: VFR (m3/hr): Motor Manufacturer: Ketville Fans Ltd Unknown Fan Type: Inlet Dia (m): Motor (kw): Centrifugal Unknown Drive Type: Outlet Dia (m): Motor (rpm): Belt Unknown Prior to fan: After Fan: Across fan: Primary Filter Manu: None Description: None At Inlet: Secondary Filter Manu: None At Outlet: Description: None At Inlet: At Outlet: Across Filter: Across Filter: Page 62 of 97 LEV040

69 Report Reference: LEV Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 041 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 08/07/2013 Next Test Date: 25/04/2016 System Location: Forge LEV Process / Type: Nickel Etch Line MC No. Extractor: Unknown Scrubber & Fan MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Acids Including Nitric & Hydrofluoric Acid Plant Photograph / Diagram a Fan unit discharging direct to atmosphere Scrubber unit TP2,3&4 duct reading TP1A TP1 TP1B TP2 TP3 TP4 Page 63 of 97 LEV041

70 Scrubber unit, fan and discharge to atmosphere TP1A & 1B TP2 TP4 (access doors) TP3 Description of LEV system & Process An extraction system is used to control the release of vapours from acid etch treatment tanks, the system uses a scubber unit and fan to extract and clean the vapours before discharging the residual air direct to atmosphere. The system controls the vapour release from two processes; TP1 is an enclosed booth with lip extraction points at the rear of the booth the release vapour from the treatment tanks is drawn towards the rear of the booth away from the operators breathing zone. The second process is a partially enclosed auto etch line where there is an entry and exit point (TP2 & TP3) and access doors on the side of the enclosure to allow manual intervention when required. Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: a Model: 435/4 Rotating Vane: a Serial No: /910 Hotwire: Calibration Date: 01/07/2014 Visual (smoke / lamp): a Tested under normal working conditions with the doors closed and no external air turbulence. Page 64 of 97 LEV041

71 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Distance (m) Qualitative Test Verdict of Examination LEV System Visual Examination Notes Discharge Termination: Motor Direction: Cleaning System: Airflow Indicators: High Velocity Discharge Correct Scrubber Yes Discharge to: Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: To Atmosphere Unknown Additional Comments: Since the last test the system has been modified to include the enclosed booth (TP1A & TP1B), the modification of the system has lead to different pressure readings in the main duct with the air flow indicator now not reading correctly. Yes Satisfactory Examination Readings & Results Duct Reading Face Reading Results 1A PASS PASS B PASS PASS PASS PASS Main Duct Reading Ref Dimensions (m) Area (m 2 ) Recommended Flow rate (m 3 /h) Pressure (Pa) MD System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) Summary The system is satisfactory at controlling the release of vapours from the two etch processing lines. There was adequate face velocity at TP1 and a smoke test demonstrated good control of the vapour with no escape into the workplace. There was satisfactory duct transfer velocity for TP2,3 & 4 and satisfactory face velocities to ensure there was no escape of vapour into the workplace a smoke test demonstrated good negative pressure. The reading taken at this test will be used as a datum point for all future tests. PASS PASS N/A PASS PASS Recommendations Replace the air flow indicator for one with correct scale. Page 65 of 97 LEV041

72 Extraction Components / Specifications Extractor Manufacturer: Fan Manufacturer: VFR (m3/hr): Motor Manufacturer: Unknown Unknown Unknown Model: Fan Type: Inlet Dia (m): Motor (kw): Centrifugal Unknown Serial No: Drive Type: Outlet Dia (m): Motor (rpm): Belt Unknown Prior to fan: After Fan: Across fan: Primary Filter Manu: Scrubber Description: Water At Inlet: Secondary Filter Manu: None At Outlet: Description: None At Inlet: At Outlet: Across Filter: Across Filter: Page 66 of 97 LEV041

73 Report Reference: LEV Fan Airflow Rate. LEV Examination & Test Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 046 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: 16/01/2014 Next Test Date: 25/08/2015 System Location: Blade Polishing (DMS) LEV Process / Type: Linish & Polishing MC No. Extractor: JB Thorne W185 MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Titanium Based Alloys Alumina Oxide Assessment of System The system was found to be SATISFACTORY at controlling the hazardous substances however, there are actions required to monitor or improve the system. See readings and summary sections. Extraction Components / Specifications Extractor Manufacturer: JB Thorne Model: W185 Serial No: J34344/99 Fan Manufacturer: JB Thorne Fan Type: Centrifugal Drive Type: Direct Fan Serial No. Inlet Dia (m): Outlet Dia (m): a a Motor Manufacturer: Motor (kw): 7.5 Motor (rpm): Prior to fan: Primary Filter Manu: N/A Description: Water Arrest System At Inlet: At Outlet: Across Filter: -415 Secondary Filter Manu: None Description: At Inlet: At Outlet: Across Filter: Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: a Model: 435/4 Rotating Vane: a Serial No: /910 Hotwire: Calibration Date: 01/07/2014 Visual (smoke / lamp): a The system was tested under normal working conditions with a maximum of 6 point in use at any one time. Page 67 of 97 LEV046

74 Plant Photograph / Diagram Extraction unit discharge to atmosphere MD1 TP1 TP2 TP3 TP4 MD2 TP7 TP8 TP5 TP6 Extraction unit discharging direct to TP2 TP1 atmosphere TP3 TP4 TP5 TP6 Page 68 of 97 LEV046

75 TP7 TP8 Description of LEV system & Process A wet dust extraction unit is used to control the release of metallic dusts from a range of linish and polishing machines. The system consists of a main header duct with drops to the individual machines and final connections to the capture hoods at each process by the use of galvanised and flexible ducting. Fitted inline between the machines and the header duct are fire dampers to shut down the extraction in the event of a fire to prevent spread to the extraction unit. The extraction unit which uses water to arrest the dust and the residual air is discharged direct to atmosphere by a discharge duct exiting the adjacent wall. LEV System Visual Examination Notes Discharge Termination: Motor Direction: Cleaning System: Airflow Indicators: Straight Duct Correct None Yes Discharge to: Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: To Atmosphere Good N/A Satisfactory Additional Comments: Page 69 of 97 LEV046

76 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Capture Distance (m) Qualitative Test Verdict of Examination Examination Readings & Results Duct Reading Face Reading Results PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS Main Duct Reading Ref Dimensions Area Recommended Flow rate (m) (m 2 ) (m 3 /h) MD System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 5235 N/A Pressure (Pa) MD Summary The system was satisfactory at controlling the release of dust from the processes with performance in line with previous tests. Although the capture distance does not reach the release point at most hoods the hood is in the path of the released dust so aiding control. Recommendations None. Page 70 of 97 LEV046

77 Report Reference: LEV Assessment of System LEV Examination & Test Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 047 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: 16/01/2014 Next Test Date: 25/08/2015 System Location: LEV Process / Type: Linish & Polishing MC No. Extractor: JB Thorne W185 MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Titanium Based Alloys Alumina Oxide Blade Polishing (DMS) The system was found to be SATISFACTORY at controlling the hazardous substances. a a Extraction Components / Specifications Extractor Manufacturer: JB Thorne Model: W185 Serial No: J35923/01 Fan Manufacturer: JB Thorne Fan Type: Centrifugal Drive Type: Direct Fan Serial No. Inlet Dia (m): Outlet Dia (m): Fan Airflow Rate. Motor Manufacturer: Motor (kw): 7.5 Motor (rpm): Prior to fan: Primary Filter Manu: N/A Description: Water Arrest System At Inlet: At Outlet: Across Filter: -169 Secondary Filter Manu: None Description: At Inlet: At Outlet: Across Filter: Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: a Model: 435/4 Rotating Vane: a Serial No: /910 Hotwire: Calibration Date: 01/07/2014 Visual (smoke / lamp): a The system was tested under normal working conditions with all points in use. Page 71 of 97 LEV047

78 Plant Photograph / Diagram Extraction unit discharge to atmosphere MD1 MD2 TP1 TP2 TP3 TP4 TP5 TP6 Extraction unit discharging direct to atmosphere TP1 TP2 TP4 TP3 TP5 TP6 Page 72 of 97 LEV047

79 Description of LEV system & Process A wet dust extraction unit is used to control the release of metallic dusts from a range of linish and polishing machines. The system consists of a main header duct with drops to the individual machines and final connections to the receptor /capture hoods at each process by the use of galvanised and flexible ducting. Fitted inline between the machines and the header duct are fire dampers to shut down the extraction in the event of a fire to prevent spread to the extraction unit. Each duct drop leads to a receptor hood which receives the dust from the grinding / polishing wheels, the hoods have an adjustable top section which is to be adjusted to surround the wheel to enclose the operating area and provide maximum available face capture distance and velocity. The system is fitted with an airflow indicator in the main header duct to monitor performance with a red / green section to indicate the health of the system. The extraction unit which uses water to arrest the dust and the residual air is discharged direct to atmosphere by a discharge duct exiting the adjacent wall. The system is designed and is capable of controlling the release of dust with all points open. LEV System Visual Examination Notes Discharge Termination: Motor Direction: Cleaning System: Airflow Indicators: Straight Duct Correct None Yes Discharge to: Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: To Atmosphere Good N/A Satisfactory Additional Comments: There is good control of dusts when the hoods are correctly positioned around the wheels. The fire damper on points TP3 & TP4 has a broken link causing partial closure of the duct, so reducing air flow rate. Page 73 of 97 LEV047

80 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Capture Distance (m) Qualitative Test Verdict of Examination Examination Readings & Results Duct Reading Face Reading Results System Performance Design / Initial Readings Main Duct Reading Ref Dimensions Area Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD Summary There was good control at each point in the system, the duct transfer and face velocities were adequate to control and transport the dust to the dust collector. A visual examination by lamp test demonstrated the dust entering the hoods as long as they were correctly positioned (polishers). Although the capture distance does not reach the release point at most hoods the hood is in the path of the released dust so aiding control MD PASS PASS PASS PASS Latest Readings 0.1 PASS PASS PASS PASS PASS PASS PASS PASS Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) Recommendations None. Page 74 of 97 LEV047

81 Report Reference: LEV Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 052 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: 08/07/2013 Next Test Date: 25/04/2016 System Location: Large Blades Forge LEV Process / Type: Forge MC No. Extractor: Unknown Centrifugal Fan MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Oil Molykote Release Agent Plant Photograph / Diagram a a MD1 Fan unit discharging direct to atmosphere TP1 TP2 TP3 TP4 Page 75 of 97 LEV052

82 Fan unit discharging direct to atmosphere TP1 TP2 TP3 TP4 TP1 TP2 TP3 TP4 Hood grilles on all extraction points partially / fully blocked preventing fume control. Page 76 of 97 LEV052

83 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Distance (m) Qualitative Test Verdict of Examination Description of LEV system & Process An extraction system is used to control the release of oil fume and molykote release agent vapours and smoke at a forge press. The system consists of extraction hoods each side of two presses which are connected to header ducts that lead to a centrifugal fan unit which discharges the substances direct to atmosphere. The system is constructed using galvanised steel ducting. As oil is burnt off from the product or as the molykote is sprayed into the forge press the releasing vapour / fume is extracted by the hoods built into the side of the press. Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: a Model: 435/4 Rotating Vane: Serial No: /910 Hotwire: Calibration Date: 01/07/2014 Visual (smoke / lamp): a The system was tested under normal working conditions with face and duct readings being taken with a smoke test to ensure the vapours / fume would be controlled by the system. LEV System Visual Examination Notes Discharge Termination: Motor Direction: Cleaning System: Airflow Indicators: Unknown Correct None No Discharge to: Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: To Atmosphere Additional Comments: The duct system was in generally good condition, however there was damage to a couple of the duct drops to the presses but the slight damage would not cause any real downturn in performance. None N/A N/A Examination Readings & Results Duct Reading Face Reading Results PASS PASS PASS PASS Main Duct Reading Ref Dimensions Area Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) N/A -580 PASS PASS PASS PASS Page 77 of 97 LEV052

84 Summary There was good control of the smoke / fume at all points in the system however, the duct reading at TP4 was lower than recommended. The high static pressure in the duct indicates a partial blockage between the test point and the extraction grille. The grilles on the hoods need to be kept clean and clear. Recommendations None Extraction Components / Specifications Extractor Manufacturer: Model: Serial No: Fan Manufacturer: VFR (m3/hr): Motor Manufacturer: Unknown Unknown Fan Type: Inlet Dia (m): Motor (kw): Centrifugal 0.6 Drive Type: Outlet Dia (m): Motor (rpm): Direct 0.6 Prior to fan: -580 After Fan: Across fan: Primary Filter Manu: None Description: None At Inlet: Secondary Filter Manu: None At Outlet: Description: None At Inlet: At Outlet: Across Filter: Across Filter: Page 78 of 97 LEV052

85 Report Reference: LEV Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 053 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: 08/07/2013 Next Test Date: 25/04/2016 System Location: Large Blades Forge LEV Process / Type: Forge MC No. Extractor: Unknown Fan Unit MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Oil Molykote Release Agent Plant Photograph / Diagram a a Fan unit discharging vapours direct to atmosphere TP1 TP2 Page 79 of 97 LEV053

86 Fan unit discharging to atmosphere Discharge stack TP1 TP2 TP1 TP2 Description of LEV system & Process An extraction system is used to control the release of oil fume and molykote release agent vapours at a forge press. The system consists of extraction hoods each side of a press which are connected to a main header duct that leads to a fan unit which discharges the controlled substances direct to atmosphere. The system is constructed using galvanised steel ducting. As oil is burnt off from the product or as the molykote is sprayed into the forge press the releasing vapour / fume is extracted by the hoods built into the side of the press. Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: a Model: 435/4 Rotating Vane: a Serial No: /910 Hotwire: Calibration Date: 01/07/2014 Visual (smoke / lamp): a The system was tested under normal working conditions with face and duct readings being taken with a smoke test to ensure the vapours / fume would be controlled by the system. A large roller door is opposite to the press, for test purposes the door was closed, however we were told that it is opened on a regular basis for additional ventilation. TP2 joint has broken and needs to be replaced, this has resulted in poor performance from this hood. Page 80 of 97 LEV053

87 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Distance (m) Qualitative Test Verdict of Examination LEV System Visual Examination Notes Discharge Termination: Motor Direction: Cleaning System: Airflow Indicators: High Velocity Discharge Correct None No Discharge to: Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: To Atmosphere N/A N/A N/A Additional Comments: Examination Readings & Results Duct Reading Face Reading Results PASS PASS System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) Summary Although the duct system was in poor condition due to damage from forklift trucks there was adequate airflow at the extraction hoods to control the release of vapours and fume released from the forge press. It is recommended that the ducting is repaired for improved airflow. The roller shutter door should be kept closed to prevent air turbulence and a reduction in control. PASS 2575 N/A PASS Recommendations Repair the duct at point TP2 Extraction Components / Specifications Extractor Manufacturer: Model: Serial No: Fan Manufacturer: VFR (m3/hr): Motor Manufacturer: Unknown Unknown Fan Type: Inlet Dia (m): Motor (kw): Axial 0.4 Drive Type: Outlet Dia (m): Motor (rpm): Direct 0.4 Prior to fan: After Fan: Across fan: Primary Filter Manu: None Description: None At Inlet: Secondary Filter Manu: None At Outlet: Description: None At Inlet: At Outlet: Across Filter: Across Filter: Page 81 of 97 LEV053

88 Report Reference: LEV Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 054 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: 08/07/2013 Next Test Date: 25/04/2016 System Location: Forge LEV Process / Type: Etch Testing MC No. Extractor: Nederman Fan Unit MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Turco Form Mask Plant Photograph / Diagram a Fan unit discharging direct to atmosphere TP1 TP1 Discharge stack Page 82 of 97 LEV054

89 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Distance (m) Qualitative Test Verdict of Examination Description of LEV system & Process A fan unit and flexible arm is used to control the release of vapours from an etch test process, the flexible arm has a hood which is positioned close to the etch test process and extracts the released vapours to a fan unit which then discharges the vapour direct to atmosphere. Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: Model: 435/4 Rotating Vane: a Serial No: /910 Hotwire: Calibration Date: 01/07/2014 Visual (smoke / lamp): a The system was tested under normal working conditions, the vapour is released at a low velocity so a 0.5m/s face velocity is required for the control of the vapours. A capture distance was taken to indicate the maximum distance the hood should be positioned from the process to ensure adequate control. LEV System Visual Examination Notes Discharge Termination: Motor Direction: Cleaning System: Airflow Indicators: Coolie Hat Correct None Yes Discharge to: Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: To Atmosphere Attention needed Additional Comments: The system was in good working order, the flexible arm was good with no signs of wear / splits on the flexible duct, there was good articulation of the arm allowing correct positioning. N/A Satisfactory Examination Readings & Results Duct Reading Face Reading Results PASS PASS Summary The system is satisfactory at controlling the released vapours, there was good face velocity and the capture distance was 200mm. The hood must be positioned within this distance from the point of the vapour release to allow correct control of the vapour. Recommendations None Page 83 of 97 LEV054

90 Extraction Components / Specifications Extractor Manufacturer: Model: Serial No: Fan Manufacturer: VFR (m3/hr): Motor Manufacturer: Nederman Nederman Fan Type: Inlet Dia (m): Motor (kw): Centrifugal Drive Type: Outlet Dia (m): Motor (rpm): Direct Prior to fan: After Fan: Across fan: Primary Filter Manu: None Description: None At Inlet: Secondary Filter Manu: None At Outlet: Description: None At Inlet: At Outlet: Across Filter: Across Filter: Page 84 of 97 LEV054

91 Report Reference: LEV Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 055 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: 08/07/2013 Next Test Date: 25/04/2016 System Location: Large Rings Machining LEV Process / Type: Mazak Integrex 1060V II MC No. Extractor: Absolent ODF2000 MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Oil based Coolant Plant Photograph / Diagram a Extractor discharging back into the workplace TP1 Extraction unit Page 85 of 97 LEV055

92 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Distance (m) Qualitative Test Verdict of Examination Description of LEV system & Process An oil mist extraction unit is used to control the release of coolant oil mist from within a machining centre. The system has an extraction hood built into the cutting side of the machine with solid duct leading from the hood to the extraction unit. The extractor has a pre filter module and a HEPA filter module for cleaning of the oil mist before returning the residual air back into the workplace. The machine uses a loading pallet to allow the operator to load / unload the components away from the machining area, this separates the operator from the area where the coolant mist is released. Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: a Model: 435/4 Rotating Vane: Serial No: /910 Hotwire: Calibration Date: 01/07/2014 Visual (smoke / lamp): The system was tested under normal working conditions to achieve a duct transfer velocity of approx 10m/s. As the operator is segregated from the machining area a visual examination of the machine was made to ensure there was no escape of mist during the pallet change LEV System Visual Examination Notes Discharge Termination: Motor Direction: Cleaning System: Airflow Indicators: From Filter Correct None Yes Discharge to: Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: Back to Workplace Good N/A Satisfactory Additional Comments: None. Examination Readings & Results Duct Reading Face Reading Results PASS PASS System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 1299 N/A Page 86 of 97 LEV055

93 Summary The system was satisfactory with no evidence of any oil mist escape into the workplace during machining. The machine has a pallet changer which separates the operator from the machining area where there would be a mist build up. Recommendations None. Extraction Components / Specifications Extractor Manufacturer: Fan Manufacturer: VFR (m3/hr): Motor Manufacturer: Absolent Model: Fan Type: Inlet Dia (m): Motor (kw): ODF2000 Centrifugal 2.2 Serial No: Drive Type: Outlet Dia (m): Motor (rpm): Direct Prior to fan: Primary Filter Manu: Absolent After Fan: Description: Pre-filter Across fan: At Inlet: Secondary Filter Manu: Absolent At Outlet: Description: Main Filter Across Filter: -178 At Inlet: Final Filter Manu: Absolent At Outlet: Description: HEPA Across Filter: -88 At Inlet: +237 At Outlet: 0 Across Filter: 237 Page 87 of 97 LEV055

94 Report Reference: LEV Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 056 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: 08/07/2013 Next Test Date: 25/04/2016 System Location: Large Rings Machining LEV Process / Type: Mazak Integrex 1550V II MC No. Extractor: Absolent ODF2000 MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Oil based Coolant Plant Photograph / Diagram a Extractor discharging back into the workplace TP1 Extraction unit Machining Centre Page 88 of 97 LEV056

95 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Distance (m) Qualitative Test Verdict of Examination Description of LEV system & Process An oil mist extraction unit is used to control the release of coolant oil mist from within a machining centre. The system has an extraction hood built into the cutting side of the machine with solid duct leading from the hood to the extraction unit. The extractor has a pre filter module and a HEPA filter module for cleaning of the oil mist before returning the residual air back into the workplace. The machine uses a loading pallet to allow the operator to load / unload the components away from the machining area, this separates the operator from the area where the coolant mist is released. Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: a Model: 435/4 Rotating Vane: Serial No: /910 Hotwire: Calibration Date: 01/07/2014 Visual (smoke / lamp): The system was tested under normal working conditions to achieve a duct transfer velocity of approx 10m/s. As the operator is segregated from the machining area a visual examination of the machine was made to ensure there was no escape of mist during the pallet change LEV System Visual Examination Notes Discharge Termination: Motor Direction: Cleaning System: Airflow Indicators: From Filter Correct None Yes Discharge to: Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: Back to Workplace Good N/A Satisfactory Additional Comments: None. Examination Readings & Results Duct Reading Face Reading Results PASS PASS System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 1153 N/A Page 89 of 97 LEV056

96 Summary The system was satisfactory with no evidence of any oil mist escape into the workplace during machining. The machine has a pallet changer which separates the operator from the machining area where there would be a mist build up. Recommendations None. Extraction Components / Specifications Extractor Manufacturer: Fan Manufacturer: VFR (m3/hr): Motor Manufacturer: Absolent Model: Fan Type: Inlet Dia (m): Motor (kw): ODF2000 Centrifugal 2.2 Serial No: Drive Type: Outlet Dia (m): Motor (rpm): Direct Prior to fan: Primary Filter Manu: Absolent After Fan: Description: Pre-Filter Across fan: At Inlet: Secondary Filter Manu: Absolent At Outlet: Description: Main Filter Across Filter: -294 At Inlet: Final Filter Manu: Absolent At Outlet: Description: HEPA Across Filter: -82 At Inlet: +285 At Outlet: 0 Across Filter: 285 Page 90 of 97 LEV056

97 Report Reference: LEV Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 057 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: 08/07/2013 Next Test Date: 25/04/2016 System Location: Large Blades Forge LEV Process / Type: Spencer & Halstead Rotary Shotblast MC No. Extractor: Integrated Spencer & Halstead MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Chilled Iron Plant Photograph / Diagram a Description of LEV system & Process A shotblast unit is used for surface preparation, it has an integrated dust extraction unit for the control of iron dust which is released during the blasting operation. The blaster cabinet is fully enclosed during the cycle and the extraction unit operates during the cycle to remove any dust created in the enclosure and to separate the dust from the re-usable shot which can then be re-cycled in the blasting system. The extraction unit has a cartridge filter for the filtration of the dust and a reverse pulse jet cleaning system for the cleaning of the cartridge, the residual air is then discharged back into the workplace. Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: a Model: 435/4 Rotating Vane: Serial No: /910 Hotwire: Calibration Date: 01/07/2014 Visual (smoke / lamp): a The system was tested under normal working conditions with the shotblast in operation, as the extractor is integrated there are no duct runs to take readings from so a visual assessment is made by use of a lamp test and visual examination of the extraction system. Page 91 of 97 LEV057

98 Ref Test Point (TP) Duct size (m) Area (m²) Guideline Flow rate (m3/h) Pressure (Pa) Recommended Capture Distance (m) Qualitative Test Verdict of Examination LEV System Visual Examination Notes Discharge Termination: Direct from Fan Discharge to: Back to Workplace Motor Direction: Correct Filter Condition (Visual): Good Cleaning System: Reverse Pulse Jet Cleaning System Working: Yes Airflow Indicators: No Airflow Indicators Working: N/A Additional Comments: Examination Readings & Results Duct Reading Face Reading Results x PASS PASS Summary The system was satisfactory for the control of the dust from the blaster. Recommendations None Extraction Components / Specifications Extractor Manufacturer: Fan Manufacturer: VFR (m3/hr): Motor Manufacturer: Spencer & Halstead Spencer & Halstead Gamak Model: Fan Type: Inlet Dia (m): Motor (kw): Centrifugal 1.5 Serial No: Drive Type: Outlet Dia (m): Motor (rpm): Direct 2790 Prior to fan: Primary Filter Manu: Unknown After Fan: Description: Cartridge filter Across fan: At Inlet: -188 At Outlet: Across Filter: -952 Secondary Filter Manu: None Description: None At Inlet: At Outlet: Across Filter: Page 92 of 97 LEV057

99 Report Reference: LEV Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 059 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 25/02/2015 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: 08/07/2013 Next Test Date: 25/04/2016 System Location: Large Blades Forge LEV Process / Type: Spencer & Halstead Rotary Shotblast MC No. Extractor: Integrated Spencer & Halstead MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Chilled Iron Plant Photograph / Diagram a Description of LEV system & Process A shotblast unit is used for surface preparation, it has an integrated dust extraction unit for the control of iron dust which is released during the blasting operation. The blaster cabinet is fully enclosed during the cycle and the extraction unit operates during the cycle to remove any dust created in the enclosure and to separate the dust from the re-usable shot which can then be re-cycled in the blasting system. The extraction unit has a cartridge filter for the filtration of the dust and a reverse pulse jet cleaning system for the cleaning of the cartridge, the residual air is then discharged back into the workplace. Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: a Model: 435/4 Rotating Vane: Serial No: /910 Hotwire: Calibration Date: 01/07/2014 Visual (smoke / lamp): a The system was tested under normal working conditions with the shotblast in operation, as the extractor is integrated there are no duct runs to take readings from so a visual assessment is made by use of a lamp test and visual examination of the extraction system. Page 93 of 97 LEV059