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: LEV24052016 Date: 24 th May 2016 Doncasters Blaenavon Forge Side Blaenavon Pontypool NP4 9XG LEV Services Ltd. Vidanta, Lower Henlade, Taunton, Somerset TA3 5LY. Tel: 01823 442869 Email: info@levservices.co.uk
Contents 1. Introduction 2. Summary 3. LEV Examination Certificates 4. Supporting Information LEV Services Ltd. Vidanta, Lower Henlade, Taunton, Somerset TA3 5LY. Tel: 01823 442869 Email: info@levservices.co.uk
Report Reference No. LEV24052016 1. 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 24 th May 2016. 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: 01823 442869 Email: info@levservices.co.uk
2. Summary System Ref. System Description Location Comments LEV 001 250 Tonne Roller Fume Forge Satisfactory 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 LEV 014 Plasma Cutting Tool Grinding Large Blades Forge Large Rings Machining Satisfactory, see recommendations for actions to further improve the system. Satisfactory Satisfactory LEV 022 Cross Cut Saw Despatch Satisfactory LEV 024 Steel Polishing DMS Satisfactory 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 Satisfactory, see recommendations for actions to further improve the system. Satisfactory LEV 039 Etch Line Forge Satisfactory LEV 040 Etch Line Forge LEV 041 Nickel Etch Line Forge 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 060 Mazak Oil Mist Extraction Mazak Oil Mist Extraction Rotary Blaster Weingarton Fume Extract Large Rings Machining Large Rings Machining Large Blades Forge Large Blades Forge LEV 071 Fume Cupboard Laboratory Satisfactory Satisfactory Satisfactory Satisfactory LEV 073 Saw Extraction Laboratory Satisfactory Satisfactory, see recommendations for actions to further improve the system. LEV Services Ltd. Vidanta, Lower Henlade, Taunton, Somerset TA3 5LY. Tel: 01823 442869 Email: info@levservices.co.uk
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: 01823 442869 Email: info@levservices.co.uk
3. LEV Examination Certificates LEV Services Ltd. Vidanta, Lower Henlade, Taunton, Somerset TA3 5LY. Tel: 01823 442869 Email: info@levservices.co.uk
Report Reference: LEV 24052016 Company Doncasters Blaenavon Test Date: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: 08/07/2015 Next Test Date: 24/07/2017 System Location: LEV Process / Type: 250 Tonne Roller MC No. Extractor: W&W Bifurcated Fan MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Oil Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 001 to Regulation 9 of the COSHH Regulations 2002 (as amended) Forge Shop Plant Photograph / Diagram a Fan unit discharging direct to atmosphere TP1 TP1 Discharge direct to atmosphere Page 1 of 101 LEV Services LEV001 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 general smoke which is generated during a hot rolling operation. A large canopy hood is fitted to a pivoting arm to allow the hood to be positioned directly above the process to receive the smoke and fume, the smoke and fume is then transferred to a fan unit where it is then discharged direct to atmosphere by the use of a discharge stack. Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: Model: 435/4 Rotating Vane: a Serial No: 2593870 Hotwire: Calibration Date: 10/08/2015 Visual (smoke / lamp): a The system was tested under normal working conditions by the means of a qualitative smoke test, this was able to be conducted by a large ring that was being rolled at the time of test. There is an external door close by, however it is a fire exit door and is not kept open. LEV System Visual Examination Notes Discharge Termination: Motor Direction: Cleaning System: Airflow Indicators: Straight Duct Correct None No Discharge to: Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: To Atmosphere Additional Comments: Strip curtain has been burnt through use, operators tend not to use the system as it poses a fire risk when in use. The fan has been replaced by a centrifugal fan with greater air flow rate. None N/A N/A Examination Readings & Results Duct Reading Face Reading Results 1 10 0 0.85 0.5 PASS PASS Summary The system is deemed satisfactory at controlling the release of smoke / fume from the rolling operation, a qualitative examination showed that smoke / fume was mainly contained in the canopy hood with very little escape to the workplace and the smoke that did escape was away from the operator. Recommendations None. Page 2 of 101 LEV Services LEV001 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Extraction Components / Specifications Extractor Manufacturer: Model: Serial No: Fan Manufacturer: VFR (m3/hr): Motor Manufacturer: W7W Unknown Fan Type: Inlet Dia (m): Motor (kw): Bifurcated 0.4 2.2 Drive Type: Outlet Dia (m): Motor (rpm): Direct 0.4 2830 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 3 of 101 LEV Services LEV001 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 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: 22/06/2016 Tested by: A.Bawler Signature Last Test Date: Next Test Date: System Location: LEV Process / Type: Extractor: 26/08/2015 22/12/2016 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: 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: a Serial No: 02593870 Hotwire: Calibration Date: 10/08/2015 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. a Page LEV 4 Services of 101 Limited, LEV003 Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Plant Photograph / Diagram Discharge direct to atmosphere MD1 TP2 TP1 Extraction unit discharging direct to TP1 TP2 atmosphere Page LEV 5 Services of 101 Limited, LEV003 Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 Discharge to: To Atmosphere Motor Direction: Correct Filter Condition (Visual): As new Cleaning System: None Cleaning System Working: N/A Airflow Indicators: Yes Airflow Indicators Working: Satisfactory Additional Comments: The system is in good working order. The ducting around the grinder has been replaced since the last test. Examination Readings & Results Duct Reading Face Reading Results 1 0.15 0.0177 24.7 15 1573.884-1179 14.8 1 0.23 PASS PASS 2 0.2 0.03141 10.3 15 1164.683-1048 9.6 1 PASS PASS Main Duct Reading Ref Dimensions Area Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD1 0.25 0.049 18.5 15 3263.4-1949 System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 3439-1760 3263.4 94.89 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. There are a high number of air changes due to the open doorway which creates high levels of dilution ventilation. Recommendations None. Page LEV 6 Services of 101 Limited, LEV003 Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 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: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 26/08/2015 Next Test Date: 24/11/2016 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: 02593870 Hotwire: Calibration Date: 10/08/2015 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 LEV 7 Services of 101 Limited, LEV004 Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Plant Photograph / Diagram Discharge direct to atmosphere TP2 Face reading TP1 TP1 & TP2 Extraction unit discharging direct to atmosphere Page LEV 8 Services of 101 Limited, LEV004 Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 1 0.3 0.0707 24.7 15 6286.6 2 0.3 0.0707 23.1 15 5879.4-664 -675 1.44 1 PASS PASS System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 13056 N/A 12166.1 93.18 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 LEV 9 Services of 101 Limited, LEV004 Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 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: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 25/02/2015 Next Test Date: 24/07/2017 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 10 of 101 LEV Services LEV007 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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: 2593870 Hotwire: Calibration Date: 10/08/2015 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 1 0.15 0.0177 15.1 10 962.172-759 5.8 0.5 0.22 PASS PASS System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 949 N/A 962.2 101.39 Page 11 of 101 LEV Services LEV007 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 220mm 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 0.15 3 Drive Type: Outlet Dia (m): Motor (rpm): Direct 0.15 2820 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 12 of 101 LEV Services LEV007 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 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: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 25/02/2015 Next Test Date: 24/07/2017 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 13 of 101 LEV Services LEV008 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
TP1 (Tested with curtain open 800mm) Page 14 of 101 LEV Services LEV008 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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: 2593870 Hotwire: Calibration Date: 10/08/2015 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 Reasonable 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. N/A Satisfactory Examination Readings & Results Duct Reading Face Reading Results 1 0.61 0.292 7.2 10 7568.64-153 0.5 0.5 PASS PASS System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 7989 N/A 7568.6 94.74 Page 15 of 101 LEV Services LEV008 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 0.61 1.1 Drive Type: Outlet Dia (m): Motor (rpm): Belt 0.61 1440 Prior to fan: -153 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 16 of 101 LEV Services LEV008 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 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: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 25/02/2015 Next Test Date: 24/07/2017 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 17 of 101 LEV Services LEV009 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
TP1 Discharge direct to atmosphere Page 18 of 101 LEV Services LEV009 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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: 2593870 Hotwire: Calibration Date: 10/08/2015 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. N/A Satisfactory Examination Readings & Results Duct Reading Face Reading Results 1 0.61 0.292 15 0-103 0.5 0.5 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 19 of 101 LEV Services LEV009 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 0.61 1.1 Drive Type: Outlet Dia (m): Motor (rpm): Belt 0.61 1440 Prior to fan: -103 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 20 of 101 LEV Services LEV009 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 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: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 25/02/2015 Next Test Date: 24/07/2017 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 21 of 101 LEV Services LEV010 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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: 2593870 Hotwire: Calibration Date: 10/08/2015 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 1 10 0-1133 7.1 0.5 0.25 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 22 of 101 LEV Services LEV010 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 0.15 0.55 Drive Type: Outlet Dia (m): Motor (rpm): Direct 0.15 2860 Prior to fan: -1133 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 23 of 101 LEV Services LEV010 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 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: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 25/02/2015 Next Test Date: 24/07/2017 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 24 of 101 LEV Services LEV012 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
TP1 TP2 Fan unit in-line Discharge direct to atmosphere Page 25 of 101 LEV Services LEV012 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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: 2593870 Hotwire: Calibration Date: 10/08/2015 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 1 0.355 0.099 8.57 10 3055.428 NA 7.4 0.5 PASS PASS 0.7 2 0.15 0.0177 9.1 10 579.852-153 1.56 0.5 PASS PASS Main Duct Reading Ref Dimensions Area Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD1 0.355 0.099 10.2 10 3635.28-215 System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 3564 N/A 3635.3 102.00 Page 26 of 101 LEV Services LEV012 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 27 of 101 LEV Services LEV012 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 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: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 25/02/2015 Next Test Date: 24/07/2017 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 MD2 MD1 TP3 TP4 TP2 TP1 TP4 TP3 TP2 TP1 Page 28 of 101 LEV Services LEV014 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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: 2593870 Hotwire: a Calibration Date: 10/08/2015 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. Tested 14 monthly as the grinding is carried out less than 12 hours per week. 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): Additional Comments: The duct readings of TP2, TP3, TP4 are calculated from the main duct readings. Cleaning System Working: Airflow Indicators Working: Back to Workplace Good Yes Satisfactory Examination Readings & Results Duct Reading Face Reading Results 1 0.1 0.0078 38.4 15 1078.27-3539 4.2 4 PASS PASS 2 0.1 0.0078 33.80 15 949.10-4437 4 4 3 0.1 0.0078 11.50 15 322.92-2802 6 4 4 0.1 0.0078 15.60 15 438.05-3047 9.2 4 PASS PASS Main Duct Reading Ref Dimensions Area Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD1 0.15 0.0177 30.0 15 1911.6 MD2 0.25 0.049 13.3 15 2346.12-2773 System Performance Design / Initial Readings Latest Readings -3108 Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) PASS PASS 2073 N/A 2346.1 113.18 PASS PASS Page 29 of 101 LEV Services LEV014 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 None. Extraction Components / Specifications Extractor Manufacturer: DCE Model: UMA456 K11 Serial No: 24626 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: -2910 After Fan: Across fan: Primary Filter Manu: DCE Description: Polyester Needle felt multi-pocket bag At Inlet: -2818 At Outlet: -2910 Across Filter: 92 Secondary Filter Manu: None Description: None At Inlet: At Outlet: Across Filter: Page 30 of 101 LEV Services LEV014 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 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: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 25/02/2015 Next Test Date: 24/07/2017 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 31 of 101 LEV Services LEV022 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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: 2593870 Hotwire: Calibration Date: 10/08/2015 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 1 0.15 0.0177 20.6 15 1312.632-1105 1.5 1 0.14 PASS PASS System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 1421 N/A 1312.6 92.37 Page 32 of 101 LEV Services LEV022 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 fit for purpose and satisfactory for use. Recommendations None. Extraction Components / Specifications Extractor Manufacturer: DCE Model: UMA153 K5 Serial No: 34762 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: -1192 At Outlet: -1762 Across Filter: 570 Secondary Filter Manu: None Description: None At Inlet: At Outlet: Across Filter: Page 33 of 101 LEV Services LEV022 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 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: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 26/08/2015 Next Test Date: 24/11/2016 System Location: 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. a a 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): Fan Airflow Rate. 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: 980 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: 02593870 Hotwire: Calibration Date: 10/08/2015 Visual (smoke / lamp): a Tested under normal working conditions with all points open (the linisher has ben removed). Page LEV 34 Services of 101 Limited, Vidanta, LEV024Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 LEV 35 Services of 101 Limited, Vidanta, LEV024Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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. Good Yes Satisfactory Examination Readings & Results Duct Reading Face Reading Results 1 2 0.2 0.0314 15 N/A N/A N/A N/A 3 4 0.15 0.0177 15 N/A N/A N/A N/A 5 6 0.15 0.0177 12.8 15 815.616-1772 1.6 1 0.12 PASS PASS N/A N/A 7 8 0.2 0.0314 22.1 15 2498.184-1586 6.6 1 PASS PASS 9.3 1 0.22 PASS PASS Main Duct Reading Ref Dimensions Area Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD1 0.355 0.099 9.4 15 3350.16-2291 System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 5381-1601 3350.16 62.26 Page LEV 36 Services of 101 Limited, Vidanta, LEV024Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Summary The system was satisfactory at controlling the release of dusts from the grinder and linisher, there was good duct transfer and face velocities at each point and subsequent smoke tests demonstrated good visualisation of air flow. Although the overall air volume is lower than initial radings this is due to the removal of machines from the system. Recommendations None. Page LEV 37 Services of 101 Limited, Vidanta, LEV024Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 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: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 25/02/2015 Next Test Date: 24/07/2017 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 38 of 101 LEV Services LEV031 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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: 2593870 Hotwire: Calibration Date: 10/08/2015 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 39 of 101 LEV Services LEV031 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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: Unknown Correct Scrubber 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 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. Yes Satisfactory Examination Readings & Results Duct Reading Face Reading Results 1 10 0 0.5 PASS PASS 2 10 0 0.5 3 10 0 0.5 4 10 0 0.5 PASS PASS 5 10 0 0.5 6 10 0 0.5 PASS PASS 7 10 0 0.5 PASS PASS 8 10 0 0.5 9 10 0 0.5 10 10 0 0.5 PASS PASS Main Duct Reading Ref Dimensions Area Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD1 0.6 0.283 10.9 10 11104.92 MD2 0.7 0.385 8.9 10 12335.4-895 System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) -676 PASS PASS PASS PASS PASS 10289 N/A 11104.9 107.93 PASS PASS PASS PASS PASS Page 40 of 101 LEV Services LEV031 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 0.7 15 Serial No: Drive Type: Outlet Dia (m): Motor (rpm): Belt 0.7 1400 Prior to fan: Primary Filter Manu: Ketville After Fan: Description: Scrubber Across fan: At Inlet: -676 At Outlet: -895 Across Filter: 219 Secondary Filter Manu: None Description: None At Inlet: At Outlet: Across Filter: Page 41 of 101 LEV Services LEV031 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 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: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 26/08/2015 Next Test Date: 24/11/2016 System Location: 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 0139 Fan Manufacturer: Climavent Fan Type: Centrifugal Drive Type: Direct Fan Serial No. Inlet Dia (m): Outlet Dia (m): Fan Airflow Rate. Large Blades Forge LEV Process / Type: Grinding MC No. Extractor: Climavent LW22 MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas 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 The system was stood down and run for test purposes only. All test points open. 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: 02593870 Hotwire: a Calibration Date: 10/08/2015 Visual (smoke / lamp): a Page LEV 42 Services of 101 Limited, Vidanta, LEV033Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Plant Photograph / Diagram Extraction unit discharging direct to atmosphere MD1 TP4 TP3 TP2 TP1 Extraction unit Discharge stack to atmosphere Page LEV 43 Services of 101 Limited, Vidanta, LEV033Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 The duct to the linisher TP4 is heavily damaged, a duct transfer velocity was not possible to measure. Page LEV 44 Services of 101 Limited, Vidanta, LEV033Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 1 0.15 0.0177 15.9 15 1013.148 2 0.15 0.0177 13.6 15 866.592 3 0.125 0.0123 18.2 15 805.896 4 0.125 0.0123 N/A 15 #VALUE! -310 Main Duct Reading Ref Dimensions Area Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD1 0.3 0.0707 13.9 15 3537.8-707 System Performance Design / Initial Readings -301 4.7 2 PASS PASS -312 4.4 2 PASS PASS -418 4.2 2 PASS PASS 3.1 2 PASS PASS Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 3500-890 3537.8 101.08 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 Replace ducting to TP4. Page LEV 45 Services of 101 Limited, Vidanta, LEV033Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 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: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 26/08/2015 Next Test Date: 24/11/2016 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: 02593870 Hotwire: Calibration Date: 10/08/2015 Visual (smoke / lamp): a The system was tested under normal working conditions, for testing of the linisher the saw was closed off. Page LEV 46 Services of 101 Limited, Vidanta, LEV034Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 LEV 47 Services of 101 Limited, Vidanta, LEV034Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 1 0.15 0.0177 13.6 15 866.59-302 3.2 2 0.08 PASS PASS 2 0.1 0.0079 14.9 15 423.76-362 0.5 1 PASS PASS 3 0.15 0.0177 16.1 15 1025.89-253 3.4 2 0.08 PASS PASS 4 0.1 0.0079 12.9 15 366.88-330 0.4 1 PASS PASS 5 0.2 0.0314 10.2 15 1153.01-114 5.2 1 PASS PASS Main Duct Reading Ref Dimensions Area Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD1 0.3 0.0707 14.5 15 3690.5-696 MD2 0.25 0.049 13.5 15 2381.4-442 System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 4683-934 3690.5 78.81 Page LEV 48 Services of 101 Limited, Vidanta, LEV034Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 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 TP5 was lower than recommended however a dust lamp test did not show any escape of dust at these points. 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 LEV 49 Services of 101 Limited, Vidanta, LEV034Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 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: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 26/08/2015 Next Test Date: 24/11/2016 System Location: 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): Fan Airflow Rate. Large Blades Forge 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: 02593870 Hotwire: Calibration Date: 10/08/2015 Visual (smoke / lamp): a The system was tested under normal working conditions. Page LEV 50 Services of 101 Limited, Vidanta, LEV035Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Plant Photograph / Diagram Extraction unit discharging direct to atmosphere MD1 MD2 TP1 TP2 TP3 TP4 TP3 MD3 Extraction unit Discharge stack to atmosphere Page LEV 51 Services of 101 Limited, Vidanta, LEV035Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
TP1 TP2 TP3 TP5 TP4 TP7 TP6 TP8 Page LEV 52 Services of 101 Limited, Vidanta, LEV035Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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. Page LEV 53 Services of 101 Limited, Vidanta, LEV035Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 1 0.1 0.0079 23.20 15 659.808-746 6.3 1 0.15 PASS PASS 2 15 3.4 1 PASS PASS 0.1 0.0079 14.80 420.912-794 3 15 3.4 1 PASS PASS 4 0.15 0.0177 14.30 15 911.196-244 3 2 PASS PASS 5 0.15 0.0177 13.80 15 879.336-268 2.6 2 PASS PASS 6 0.15 0.0177 14.6 10 930.312-470 6.4 1 0.15 PASS PASS 7 0.15 0.0177 16.6 10 1057.752-507 3.6 2 PASS PASS 8 0.12 0.0123 17.6 20 779.328-590 3.4 2 PASS PASS Main Duct Reading Ref Dimensions Area Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD1 0.3 0.071 14.7 15 3757.32-1455 System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 3552-1033 3757.32 105.78 Page LEV 54 Services of 101 Limited, Vidanta, LEV035Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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. When using the linisher TP4 & TP5 the points TP6 - TP8 must be closed off and likewise if TP6 - TP8 is in use the linisher TP4 & TP5 must be closed off. 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 LEV 55 Services of 101 Limited, Vidanta, LEV035Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 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: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 25/02/2015 Next Test Date: 24/07/2017 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 101 LEV Services LEV039 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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: 2593870 Hotwire: Calibration Date: 10/08/2015 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 101 LEV Services LEV039 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 Yes Discharge to: Additional Comments: Some deposits of fume settlement on lip extraction hoods TP4, TP5 & TP6. Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: To Atmosphere N/A N/A Satisfactory Examination Readings & Results Duct Reading Face Reading Results 1 0.14 x 0.49 0.0686 7.4 15 1827.504-470 PASS PASS 2 0.14 x 0.49 0.0686 11.4 15 2815.344-446 3 0.14 x 0.49 0.0686 10.1 25 2494.296-423 4 0.14 x 0.49 0.0686 10.6 10 2617.776-392 PASS PASS 5 0.14 x 0.49 0.0686 8.4 15 2074.464-389 6 0.18 x 0.49 0.0882 8.6 10 2730.672-371 PASS PASS 7 0.4 0.126 1.2 10 544.32-357 0.5 0.5 PASS PASS Main Duct Reading Ref Dimensions Area Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD1 0.63 0.312 17.5 10 19656 System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) -566 PASS PASS PASS 17035-625 19656.00 115.39 PASS PASS PASS Page 58 of 101 LEV Services LEV039 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 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 0.63 Unknown Drive Type: Outlet Dia (m): Motor (rpm): Belt 0.63 Unknown Prior to fan: -566 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 101 LEV Services LEV039 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 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: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 25/02/2015 Next Test Date: 24/07/2017 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 101 LEV Services LEV040 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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: 2593870 Hotwire: Calibration Date: 10/08/2015 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 101 LEV Services LEV040 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 1 10 0 PASS PASS 2 10 0 3 10 0 4 10 0 PASS PASS 5 10 0 6 10 0 PASS PASS 7 10 0 PASS PASS 8 10 0 9 10 0 10 10 0 PASS PASS Main Duct Reading Ref Dimensions Area Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD1 0.5 x 0.7 0.35 4.0 10 5040 System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 11214-222 5040.00 44.94 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. -55 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 101 LEV Services LEV040 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 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: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature Last Test Date: 25/02/2015 Next Test Date: 24/07/2017 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 101 LEV Services LEV041 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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: 2593870 Hotwire: Calibration Date: 10/08/2015 Visual (smoke / lamp): a Tested under normal working conditions with the doors closed and no external air turbulence. Page 64 of 101 LEV Services LEV041 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 0.3 0.071 8.4 10 2147.04-113 PASS PASS 1.6 0.5 1B 0.3 0.071 22.8 10 5827.68-724 PASS PASS 2 3 0.56 0.246 11.7 10 10361.52-569 0.6 0.5 PASS PASS Main Duct Reading Ref Dimensions Area Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD1 0.76 0.453 10 0-718 System Performance Design / Initial Readings 1.3 0.5 4 0.8 0.5 Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 16218 N/A 18336.24 113.06 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 PASS PASS Recommendations Replace the air flow indicator for one with correct scale. Page 65 of 101 LEV Services LEV041 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 101 LEV Services LEV041 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: Titanium Based Alloys Alumina Oxide Assessment of System LEV Examination & Test Last Test Date: 26/08/2015 Next Test Date: 24/11/2016 System Location: LEV 24052016 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: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp 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 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: J34344/99 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: -1684 Primary Filter Manu: N/A Description: Water Arrest System At Inlet: -1229 At Outlet: -1684 Across Filter: -455 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: 02593870 Hotwire: Calibration Date: 10/08/2015 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 LEV 67 Services of 101 Limited, Vidanta, LEV046Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 LEV 68 Services of 101 Limited, Vidanta, LEV046Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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: None. Page LEV 69 Services of 101 Limited, Vidanta, LEV046Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 1 0.12 2 0.12 3 0.1 4 0.1 5 0.12 6 0.12 7 0.1 8 0.1 0.0113 22 15 894.96-676 0.0113 29.7 15 1208.20-1367 0.0079 21.2 15 602.93-326 0.0079 23.5 15 668.34-442 0.0113 24.8 15 1008.86-1332 0.0113 27.9 15 1134.97-1531 0.0079 20.1 15 571.64-691 0.0079 25.4 15 722.38-1049 4.5 2 0.12 PASS PASS 7.1 2 0.12 PASS PASS 2.6 2 0.1 PASS PASS 3.6 2 0.12 PASS PASS 6.2 2 0.12 PASS PASS 7.2 2 0.14 PASS PASS 4.5 2 0.1 PASS PASS 4.7 2 0.1 PASS PASS Main Duct Reading Ref Dimensions Area Recommended Flow rate (m) (m 2 ) (m 3 /h) Pressure (Pa) MD1 0.3 0.0707 13.0 15 3308.76-1365 MD2 0.25 0.049 20.4 15 System Performance Design / Initial Readings 5235 N/A 3598.56 Latest Readings -1557 Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 6907.32 131.94 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. Dust lamp and smoke tests demonstrated good control and visualisation of air flow. Recommendations None. Page LEV 70 Services of 101 Limited, Vidanta, LEV046Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 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: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: 26/08/2015 Next Test Date: 24/11/2016 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. 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: -1483 Primary Filter Manu: N/A Description: Water Arrest System At Inlet: -1373 At Outlet: -1483 Across Filter: -110 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: 02593870 Hotwire: Calibration Date: 10/08/2015 Visual (smoke / lamp): a The system was tested under normal working conditions with all points in use. Page LEV 71 Services of 101 Limited, Vidanta, LEV047Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 LEV 72 Services of 101 Limited, Vidanta, LEV047Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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. Page LEV 73 Services of 101 Limited, Vidanta, LEV047Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 1 2 0.1 5 6 19.6 0.1 0.0079 16.7 0.1 0.0079 15 557.424 15 474.948-708 -826 3 0.12 0.0113 31.3 15 1273.284-1407 5.3 2 3.7 2 0.1 PASS PASS 4.3 2 0.1 PASS PASS 0.12 PASS PASS 4 0.12 0.0113 30.4 15 1236.672-1364 6 2 0.12 PASS PASS 3.7 2 0.1 PASS PASS 4.9 2 0.1 PASS PASS Main Duct Reading Ref Dimensions (m) Area (m 2 ) Recommended Flow rate (m 3 /h) Pressure (Pa) MD1 0.3 0.0707 19.4 15 4937.69-1450 System Performance 0.1 0.0079 19.9 15 565.956 0.0079 21.3 MD2 0.2 0.0314 24.2 15 2735.568 Design / Initial Readings 16 605.772 Latest Readings -1011 Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 4352-1554 4937.69 113.46 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. -534-709 Recommendations None. Page LEV 74 Services of 101 Limited, Vidanta, LEV047Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 Oil 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: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: 25/02/2015 Next Test Date: 24/07/2017 System Location: LEV Process / Type: Forge MC No. Extractor: Unknown Centrifugal Fan MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Molykote Release Agent Plant Photograph / Diagram Large Blades Forge a a MD1 Fan unit discharging direct to atmosphere TP1 TP2 TP3 TP4 Page 75 of 101 LEV Services LEV052 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 101 LEV Services LEV052 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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: 2593870 Hotwire: Calibration Date: 10/08/2015 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 1 0.25 0.049 10.7 10 1887.48-480 PASS PASS 2 0.25 0.049 14.8 10 2610.72-433 3 0.25 0.049 11.6 10 2046.24-269 4 0.25 0.049 5.5 10 970.2-496 PASS PASS Main Duct Reading Ref Dimensions Area Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD1 0.6 0.28 7.5 10 7514.64 System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 11390 N/A N/A PASS PASS 7514.64 65.98 PASS PASS Page 77 of 101 LEV Services LEV052 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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. There has been a drop in erformance over the past few years, the air flow rate and static pressure at each point has dropped indicating that there is a performance issue with the fan, this could be a build up on the fan blades and internal casing, this needs to be investigated and cleaned is necessary. Recommendations Inspect the fan internals to check casing and blades for build up, clean if necessary. 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: N/A 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 101 LEV Services LEV052 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 Company Doncasters Blaenavon Test Date: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: 25/02/2015 Next Test Date: 24/07/2017 System Location: LEV Process / Type: Forge MC No. Extractor: Unknown Fan Unit MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Oil Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 053 to Regulation 9 of the COSHH Regulations 2002 (as amended) Molykote Release Agent Plant Photograph / Diagram Large Blades Forge a a Fan unit discharging vapours direct to atmosphere TP1 TP2 Page 79 of 101 LEV Services LEV053 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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: 2593870 Hotwire: Calibration Date: 10/08/2015 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 101 LEV Services LEV053 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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: None. Examination Readings & Results Duct Reading Face Reading Results 1 0.25 0.049 6.9 10 1217.16-323 PASS PASS 2 0.25 0.049 8.8 10 1552.32-371 System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 2575 N/A 2769.48 107.55 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 PASS 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 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 101 LEV Services LEV053 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 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: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: 25/02/2015 Next Test Date: 24/07/2017 System Location: 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 Forge Plant Photograph / Diagram a Fan unit discharging direct to atmosphere TP1 TP1 Discharge stack Page 82 of 101 LEV Services LEV054 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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: 2593870 Hotwire: Calibration Date: 10/08/2015 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 1 10 0 5.2 0.5 0.2 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 101 LEV Services LEV054 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 0.15 0.55 Drive Type: Outlet Dia (m): Motor (rpm): Direct 0.15 2860 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 101 LEV Services LEV054 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 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: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: 25/02/2015 Next Test Date: 24/07/2017 System Location: 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 Large Rings Machining a Extractor discharging back into the workplace TP1 Extraction unit Page 85 of 101 LEV Services LEV055 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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: 2593870 Hotwire: Calibration Date: 10/08/2015 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 1 0.2 0.0314 9.1 10 1028.664-673 PASS PASS System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 1299 N/A 1028.66 79.19 Page 86 of 101 LEV Services LEV055 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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: Absolent Model: ODF2000 Serial No: 20070965 Fan Manufacturer: Fan Type: Centrifugal Drive Type: Direct VFR (m3/hr): Inlet Dia (m): Outlet Dia (m): Motor Manufacturer: Motor (kw): 2.2 Motor (rpm): Prior to fan: After Fan: Across fan: Primary Filter Manu: Absolent Description: Pre-filter At Inlet: -1170 At Outlet: -1385 Across Filter: 215 Secondary Filter Manu: Absolent Description: Main Filter At Inlet: -1385 At Outlet: -1492 Across Filter: 107 Final Filter Manu: Absolent Description: HEPA At Inlet: +316 At Outlet: 0 Across Filter: 316 Page 87 of 101 LEV Services LEV055 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 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: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: 25/02/2015 Next Test Date: 24/07/2017 System Location: 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 Large Rings Machining a Extractor discharging back into the workplace TP1 Extraction unit Machining Centre Page 88 of 101 LEV Services LEV056 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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: 2593870 Hotwire: Calibration Date: 10/08/2015 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 1 0.2 0.0314 12.1 10 1367.784-802 PASS PASS System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 1153 N/A 1367.78 118.63 Page 89 of 101 LEV Services LEV056 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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: Absolent Model: ODF2000 Serial No: 20070964 Fan Manufacturer: Fan Type: Centrifugal Drive Type: Direct VFR (m3/hr): Inlet Dia (m): Outlet Dia (m): Motor Manufacturer: Motor (kw): 2.2 Motor (rpm): Prior to fan: After Fan: Across fan: Primary Filter Manu: Absolent Description: Pre-Filter At Inlet: -912 At Outlet: -1299 Across Filter: 387 Secondary Filter Manu: Absolent Description: Main Filter At Inlet: -1299 At Outlet: -1380 Across Filter: 81 Final Filter Manu: Absolent Description: HEPA At Inlet: +383 At Outlet: 0 Across Filter: 383 Page 90 of 101 LEV Services LEV056 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 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: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: 25/02/2015 Next Test Date: 24/07/2017 System Location: 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 Large Blades Forge 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: 2593870 Hotwire: Calibration Date: 10/08/2015 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 101 LEV Services LEV057 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 1 0.145x0.145 0.021 9.6 725.76 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: -14 At Outlet: -614 Across Filter: -600 Secondary Filter Manu: None Description: None At Inlet: At Outlet: Across Filter: Page 92 of 101 LEV Services LEV057 Limited, Vidanta, Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV Examination & Test Last Test Date: 25/02/2015 Next Test Date: 22/08/2017 System Location: Heat Assessment of System LEV 24052016 Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 060 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 22/06/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Large Blades Forge LEV Process / Type: Weingarten Press Fume Extraction MC No. 8614 Extractor: Centrifugal fan system MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas The system was found to be SATISFACTORY at controlling the hazardous substances. a Extraction Components / Specifications Extractor Manufacturer: N/A Model: N/A Serial No: N/A Fan Manufacturer: Unknown Fan Type: Centrifugal Drive Type: Direct Fan Model: Unknown Inlet Dia (m): Outlet Dia (m): Fan Serial No. Unknown Motor Manufacturer: amtecs Motor (kw): 7.5 Motor (rpm): 2900 Prior to fan: -581 Primary Filter Manu: Secondary Filter Manu: None None The system was tested under normal working conditions. Description: At Inlet: At Outlet: Across Filter: 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: Serial No: 2593870 Hotwire: Calibration Date: 10/08/2015 Visual (smoke / lamp): a Page LEV 93 Services of 101 Limited, Vidanta, LEV060Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Plant Photograph / Diagram Fan unit discharging direct to atmosphere TP1 TP2 MD1 Page LEV 94 Services of 101 Limited, Vidanta, LEV060Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 An LEV system is used to control the heat and fume generated on the forge press. The system consists of two capture hoods positioned into the sides of the press to capture the releaseof fume and heat, the substances are then transferred by ducting to a centrifugal fan unit where the substances are discharged direct to atmosphere. LEV System Visual Examination Notes Discharge Termination: Motor Direction: Cleaning System: Airflow Indicators: Grille Correct None No Discharge to: Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: To Atmosphere N/A N/A N/A Additional Comments: Very good visual examination showing control of fume when press is in use. Examination Readings & Results Duct Reading Face Reading Results 1 0.4 0.126 14.6 10 6622.56 2 0.4 0.126 9.9 10 4358.88-417 PASS PASS -329 PASS PASS Main Duct Reading Ref Dimensions Area Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD1 0.56 0.246 12.4 10 10981.44-581 System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 11689-530 10981.44 93.95 Summary The system was deemed satisfactory for the control of the released substances, there was good readings achieved for air flow rates and a qualitative test by smoke demonstrated very good control. Recommendations None. Page LEV 95 Services of 101 Limited, Vidanta, LEV060Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 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) 071 Company Doncasters Blaenavon Test Date: 24/05/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: 25/02/2015 Next Test Date: 24/07/2017 System Location: Fan Airflow Rate. Laboratory Cupboard Manu: Esco Ductless Fume Cupboard MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Various Chemicals including Nitric Acid, Acetone & Hydrofluoric Acid 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: Esco Model: ADC-4B1 Serial No: 2010-51948 Fan Manufacturer: Unknown Fan Type: Centrifugal Drive Type: Direct Fan Serial No. Unknown Inlet Dia (m): Outlet Dia (m): a Motor Manufacturer: Unknown Motor (kw): Unknown Motor (rpm): Unknown Prior to fan: Primary Filter Manu: Esco Description: Pre-filter sheet At Inlet: At Outlet: Across Filter: Secondary Filter Manu: Esco Description: Activated carbon module At Inlet: At Outlet: Across Filter: Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: Model: 435/4 Rotating Vane: a Serial No: 2593870 Hotwire: Calibration Date: 10/08/2015 Visual (smoke / lamp): a Tested under normal working conditions with cupboard loaded as normal. Page LEV 96 Services of 101 Limited, Vidanta, LEV071Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Plant Photograph / Diagram Discharge filtered air back to the workplace TP1 Fume cupboard TP1 Page LEV 97 Services of 101 Limited, Vidanta, LEV071Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
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 bench mounted fume cupboard is used for the control of acids / chemicals used within the Laboratory. The cupboard has its own integral fan unit which draws the fume vapours through a first stage pre-filter and then through an activated carbon filter module before discharging the residual air back into the workplace. LEV System Visual Examination Notes Discharge Termination: Motor Direction: Sash Door Operation: Light Operation: Airflow Indicators: Sash Height Alarm: Filter Last Replaced: Additional Comments: Sash width 1260mm. Direct from Fan Discharge to: Back to Workplace Correct Duct Condition (Visual): N/A Satisfactory Worktop Condition: Satisfactory Satisfactory Rear Baffle: Satisfactory No Airflow Indicator Working: N/A No Sash Height Alarm Working: N/A 2016 Filter Condition (Visual): Unknown Examination Readings & Results 0.91 0.91 0.99 Readings taken across the face of the open sash, not within 100mm of the edges. 0.94 0.88 0.98 0.86 0.74 0.95 Sash Operating Height: Min Reading: Max Reading: % Deviation From Mean Readings within 20% 240mm 0.74 0.99 18.4 / 9.2 Yes Duct Reading Face Reading Results 1 10 0 0.91 0.5 PASS PASS Summary There was adequate face velocity with an air flow visualisation demonstrating good containment and no escape into the workplace. a smoke test demonstrated good visualisation of air flow. The actual face velocity is higher than the velocity on the display, we would recommend that the display is calibrated, excessive face velocity can lead to premature wear of the carbon filter. Recommendations Calibrate the display to the actual face velocity. Page LEV 98 Services of 101 Limited, Vidanta, LEV071Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Report Reference: LEV 24052016 LEV Examination & Test Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV to Regulation 9 of the COSHH Regulations 2002 (as amended) 073 Company Doncasters Blaenavon Test Date: 22/06/2016 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: Water Titanium Assessment of System First Test Next Test Date: 22/08/2017 System Location: Laboratory LEV Process / Type: Mist Extraction MC No. Extractor: Centrifugal fan system MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas The system was found to be SATISFACTORY at controlling the hazardous substances. a a Extraction Components / Specifications Extractor Manufacturer: N/A Model: N/A Serial No: N/A Fan Manufacturer: Maico Fan Type: Centrifugal Drive Type: Direct Fan Model: ERR 10/1 S Inlet Dia (m): 0.1 Outlet Dia (m): 0.1 Fan Serial No. 800271 Motor Manufacturer: Unknown Motor (kw): 0.05 Motor (rpm): 2800 Prior to fan: -151 Primary Filter Manu: Secondary Filter Manu: None None The system was tested under normal working conditions. Description: At Inlet: At Outlet: Across Filter: 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: Serial No: 2593870 Hotwire: Calibration Date: 10/08/2015 Visual (smoke / lamp): a Page LEV 99 Services of 101 Limited, Vidanta, LEV 073Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk
Plant Photograph / Diagram Fan unit discharging direct to atmosphere Fan TP1 Page LEV 100 Services of 101 Limited, Vidanta, LEV 073 Lower Henlade, Taunton, Somerset, TA3 5LY.Tel: 01823 442869 Email: info@levservices.co.uk www.levservices.co.uk