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

Transcription

1 Thorough Examination and Test of Local Exhaust Ventilation Systems to Regulation 9 of the COSHH Regulations 2002 (as amended) Test of LEV Systems 6 Monthly Test Report Ref: LEV Date: 16 th January 2014 Doncasters Blaenavon Forge Side Blaenavon Pontypool NP4 9XG LEV Services Ltd. Vidanta, Lower Henlade, Taunton, Somerset TA3 5LY. Tel: info@levservices.co.uk

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

3 Report Reference No. LEV Introduction Doncasters Blaenavon specialises in the manufacture of forge ring products for Aerospace and Industrial gas turbines at its site in Blaenavon. Local exhaust ventilation (LEV) systems have been installed on various processes to control the release of substances hazardous to health. 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 16 th January The test Engineer was Alan Bawler of LEV Services Ltd, the competent person was Alan Bawler trained to BOHS P601, Initial Appraisal And Thorough Examination And Testing Of LEV. Strategy A local exhaust ventilation test was carried out for each plant on site and associated health and safety polices were taken into account for each test. Process Conditions At each stage of the examination and test process, attention was paid to ensuring the LEV system was loaded to a typical operating condition before testing was carried out. It must be emphasised that all results and conclusions pertain only to the conditions prevailing on the date of the tests. Records The record of the examination and tests should be kept by the employer for at least five years, it is the employers responsibility to ensure that the records are kept safely. In the event that the examination and tests are either destroyed or lost then a copy can be obtained from LEV Services Ltd. LEV Services Ltd. Vidanta, Lower Henlade, Taunton, Somerset TA3 5LY. Tel: info@levservices.co.uk

4 2. Summary There has been deterioration in the performance on LEV 035, due to the excessive lengths in the ducting to the linisher. Constant maintenance has been required to ensure the ducts are kept clear of settlement due to the lower than recommended duct transfer velocities, the ducting on this system was last cleaned on the 13 th January. On previous tests the face velocity and transfer velocities have been borderline, on this test it was evident that the system is not robust enough to sustain adequate control between services. It is recommended that personal air monitoring is carried out to determine the dust exposure to the operators. System Ref. System Description Location Comments LEV 003 Billet Grind Saw Shop Satisfactory. LEV 004 Grind Booth No.2 Forge Satisfactory. LEV 006 Grind Booth SRB Forge LEV 024 Steel Polishing DMS LEV 033 LEV 034 LEV 035 Grinding Cutting & Grind Grind & Linish Large Blades Forge Large Blades Forge Large Blades Forge LEV 046 Linish & Polish DMS LEV 047 Linish & Polish DMS Comments use a traffic light colour code system; Green - satisfactory with no recommendations Yellow - satisfactory with recommendations Red unsatisfactory with recommendations 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. Unsatisfactory, 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. Refer to individual LEV examination certificates for the recommendations to any LEV system. Responsibility With LEV systems / hoods that are deemed unsatisfactory it is the responsibility of the employer to remedy the failures as soon as possible. The certification is only valid for the systems / hoods that are satisfactory and all failures must be retested after remedial works have been completed to give the system / hoods a satisfactory certificate. LEV Services Ltd. Vidanta, Lower Henlade, Taunton, Somerset TA3 5LY. Tel: info@levservices.co.uk

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

6 Report Reference: LEV LEV Examination & Test Thorough Examination and Test of Local Exhaust Ventilation Systems to Regulation 9 of the COSHH Regulations 2002 (as amended) System Ref: LEV 003 Company Last Test Date: Next Test Date: System Location: LEV Process / Type: Extractor: Doncasters Blaenavon Forge Side Blaenavon Pontypool NP4 9XG Saw Shop 08/07/ /07/2014 Grinding of Billets Climavent LW22 Test Date: 16/01/2014 Tested by: Signature & Stamp MC No. MC No. A.Bawler QC 01 Released Substances To Be Controlled Steel containing cobalt, nickel Alumina Oxide Dust r r 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: r Serial No: Hotwire: Calibration Date: 01/07/2013 Visual (smoke / lamp): r 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. r Page 1 of 28 LEV003

7 Plant Photograph / Diagram Discharge direct to atmosphere MD1 TP2 TP1 Extraction unit discharging direct to TP1 TP2 atmosphere Page 2 of 28 LEV003

8 Ref Test Point (TP) Duct size (m) Area (m²) Measured Guideline Flow rate (m3/h) Pressure (Pa) Measured 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: New dust collector installed since last test. Access cover on grinder is deformed causing loss of air. Examination Readings & Results Duct Reading Face Reading Results PASS PASS PASS PASS Main Duct Reading Ref Dimensions Area Measured Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) Summary The extraction system was satisfactory at controlling the release of dust from the grinder the dust is released in the direction of the receptor hood (TP1) and extracted to the extraction unit. The hood TP1 has adequate face velocity to capture the dust released from the rotating grinding wheel. Recommendations Page 3 of 28 LEV003

9 Report Reference: LEV LEV Examination & Test Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 004 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 16/01/2014 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: 08/07/2013 Next Test Date: 16/07/2014 System Location: Alumina Oxide Assessment of System 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 The system was found to be SATISFACTORY at controlling the hazardous substances. r r QC 01 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: r Model: 435/4 Rotating Vane: r Serial No: Hotwire: Calibration Date: 01/07/2013 Visual (smoke / lamp): r The system was tested under normal working conditions to ensure the released dust is contained by the booth and there is no escape of the dust into the workplace. Page 4 of 28 LEV004

10 Plant Photograph / Diagram Discharge direct to atmosphere TP1 TP2 TP1 & TP2 TP1 & TP2 Extraction unit discharging direct to atmosphere Page 5 of 28 LEV004

11 Ref Test Point (TP) Duct size (m) Area (m²) Measured Guideline Flow rate (m3/h) Pressure (Pa) Measured 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 Discharge to: Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: To Atmosphere Good Condition N/A Satisfactory Additional Comments: Last serviced June Examination Readings & Results Duct Reading Face Reading Results PASS PASS System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) N/A Summary The system was satisfactory and it is the opinion of the assessor that the released substance is adequately controlled. The grinding must take place within the booth for control to be achieved. Recommendations None Page 6 of 28 LEV004

12 Report Reference: LEV Fan Airflow Rate. 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: 16/01/2014 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: 08/07/2013 Next Test Date: 16/07/2014 System Location: Steel containing cobalt, nickel Alumina Oxide Assessment of System 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 The system was found to be SATISFACTORY at controlling the hazardous substances however, there are actions required to monitor or improve the system. See readings and summary sections. Extraction Components / Specifications Extractor Manufacturer: Disa Model: FMC200-4A Serial No: 2260 Fan Manufacturer: Disa Fan Type: Centrifugal Drive Type: Direct Fan Serial No. Inlet Dia (m): Outlet Dia (m): r r QC 01 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: 960 Secondary Filter Manu: None Description: At Inlet: At Outlet: Across Filter: Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: r Model: 435/4 Rotating Vane: r Serial No: Hotwire: Calibration Date: 01/07/2013 Visual (smoke / lamp): r Tested under normal working conditions with all points open (the linisher has ben removed). Page 7 of 28 LEV024

13 Plant Photograph / Diagram TP7 Extraction unit discharging direct to atmosphere TP8 TP5 TP4 TP3 TP6 TP1 TP2 Extraction unit discharging direct TP2 TP1 to atmosphere TP5 TP6 TP7 TP8 Page 8 of 28 LEV024

14 Ref Test Point (TP) Duct size (m) Area (m²) Measured Guideline Flow rate (m3/h) Pressure (Pa) Measured 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 are not in use and currently closed off, the system was tested in this set up. TP5 flexible ducting is in poor condition with splits along its length. Good Yes Satisfactory Examination Readings & Results Duct Reading Face Reading Results N/A 15 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 15 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A PASS PASS PASS PASS PASS PASS PASS PASS Main Duct Reading Ref Dimensions Area Measured Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) Summary The system was satisfactory at controlling the release of dusts from the grinders and linishers, there was adequate face velocities and duct transfer velocities for the control of the dust. Although the overall air volume is lower than initial radings this is due to the removal of machines from the system. Recommendations Replace the ducting on TP5. Page 9 of 28 LEV024

15 Report Reference: LEV Fan Airflow Rate. 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: 16/01/2014 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: 08/07/2014 Next Test Date: 16/07/2014 System Location: Titanium Based Alloys Alumina Oxide Assessment of System Large Blades Forge LEV Process / Type: Grinding MC No. Extractor: Climavent LW22 MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas 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): 3700m³/hr r r QC 01 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: r Model: 435/4 Rotating Vane: r Serial No: Hotwire: r Calibration Date: 01/07/2013 Visual (smoke / lamp): r Page 10 of 28 LEV033

16 Plant Photograph / Diagram Extraction unit discharging direct to atmosphere MD1 TP5 TP4 TP3 TP1 TP2 Extraction unit Discharge stack to atmosphere Page 11 of 28 LEV033

17 TP2 TP1 TP3 TP4 TP5 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: Airflow Indicators Working: To Atmosphere Additional Comments: The capture hoods at each point were clear of any debris allowing clear airflows. There is a waste of air volume at TP4 & TP5 due to the large open face on the end of the capture hoods, these should be enclosed further to increase the face velocity. Good N/A Satisfactory Page 12 of 28 LEV033

18 Ref Test Point (TP) Duct size (m) Area (m²) Measured Guideline Flow rate (m3/h) Pressure (Pa) Measured Recommended Capture Capture Distance (m) Qualitative Test Verdict of Examination Examination Readings & Results Duct Reading Face Reading Results N/A N/A N/A N/A NA PASS NA PASS NA PASS NA PASS NA PASS Main Duct Reading Ref Dimensions Area Measured Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) Summary 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. Recommendations Raise the hood on TP3 closer to the linish belt. Enclose the wheels on TP4 & TP5 Page 13 of 28 LEV033

19 Report Reference: LEV Titanium Based Alloys Alumina Oxide Assessment of System 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: 16/01/2014 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: 08/07/2013 Next Test Date: 16/07/2014 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 The system was found to be SATISFACTORY at controlling the hazardous substances. r r QC 01 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: r Model: 435/4 Rotating Vane: r Serial No: Hotwire: Calibration Date: 01/07/2013 Visual (smoke / lamp): r The system was tested under normal working conditions, for testing of the linisher the saw was closed off. Page 14 of 28 LEV034

20 Plant Photograph / Diagram Extraction unit discharging direct to atmosphere TP5 TP4 TP3 TP2 TP1 Extraction unit Discharge stack to atmosphere TP1 TP2 TP3 TP4 TP5 Page 15 of 28 LEV034

21 Ref Test Point (TP) Duct size (m) Area (m²) Measured Guideline Flow rate (m3/h) Pressure (Pa) Measured 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. 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: Examination Readings & Results Duct Reading Face Reading Results PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS Main Duct Reading Ref Dimensions Area Measured Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) Summary The system was adequate at controlling the release of dust from the points TP1, TP3 and TP5, although for maximum performance it is recommended that the damper to TP5 is closed off when the linishers are in use. The main duct transfer velocity for TP1,2,3 & 4 met recommended guidelines and there was no signs of settlement in the ducting. The face velocity was adequate at the drop out box as the path of the released dust enters the hood / drop out box with little escape until the operator pushes hard on the components forcing the abrading process. The face velocity at TP2 and TP4 was lower than recommended however a dust lamp test did not show any escape of dust at these points. Recommendations None. Page 16 of 28 LEV034

22 Report Reference: LEV Fan Airflow Rate. 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: 16/01/2014 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: 08/07/2013 Next Test Date: 16/07/2014 System Location: Titanium Based Alloys Alumina Oxide Assessment of System Large Blades Forge LEV Process / Type: Grinding & Linishing MC No. Extractor: Climavent LW22 MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas The system was found to have some UNSATISFACTORY control points which do not control the hazardous substances and urgent actions are required to improve the system. See readings and summary sections. Extraction Components / Specifications Extractor Manufacturer: Climavent Model: LW22 Serial No: PDI 0124 Fan Manufacturer: Climavent Fan Type: Centrifugal Drive Type: Direct Fan Serial No. Inlet Dia (m): Outlet Dia (m): 3700m³/hr r r QC 01 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 tested under normal working conditions. Only two dampers open at any one time. Description: At Inlet: At Outlet: Across Filter: Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: r Model: 435/4 Rotating Vane: r Serial No: Hotwire: Calibration Date: 01/07/2013 Visual (smoke / lamp): r Page 17 of 28 LEV035

23 Plant Photograph / Diagram Extraction unit discharging direct to atmosphere TP1 TP2 MD1 MD2 TP4 TP3 MD3 Extraction unit Discharge stack to atmosphere Page 18 of 28 LEV035

24 Ref Test Point (TP) Duct size (m) Area (m²) Measured Guideline Flow rate (m3/h) Pressure (Pa) Measured Recommended Capture Capture Distance (m) Qualitative Test Verdict of Examination TP3 TP4 TP1 TP2 Description of LEV system & Process A wet dust extraction unit is used to control the release of metallic dusts from a linishing and grinding machine. 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: Additional Comments: MD1 reading is for the grinder. MD2 reading is for the linisher. Straight Duct Correct None Yes Discharge to: Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: To Atmosphere Good N/A Satisfactory 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. The grinder is not working and the extraction points closed off. TP4 has a defective drive wheel so this is not used and the face of the hood closed off resulting in just TP3 hood used on this system. Examination Readings & Results Duct Reading Face Reading Results N/A 15 N/A N/A 15 N/A N/A 15 N/A N/A N/A 2 N/A N/A N/A N/A N/A 2 N/A N/A N/A PASS FAIL N/A N/A 2 N/A N/A N/A Page 19 of 28 LEV035

25 Main Duct Reading Ref Dimensions Area Measured Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD N/A 15 N/A N/A MD MD System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) Summary There has been deterioration in the control from this system on the linisher, with all but point TP3 closed there is marginal control at the hood however, duct transfer velocities are not being met due to the excessive duct length to the linisher and this is resulting in settlement within the duct system which in turn causes partial blockage of the duct system The extractor was recently serviced where the duct system was inspected and partial blockages removed from the system. It is the opinion of the assessor that the system is not adequate to control the release of the dust due to the below 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. Page 20 of 28 LEV035

26 Report Reference: LEV Fan Airflow Rate. LEV Examination & Test Thorough Examination and Test of Local Exhaust Ventilation Systems System Ref: LEV 046 to Regulation 9 of the COSHH Regulations 2002 (as amended) Company Doncasters Blaenavon Test Date: 16/01/2014 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: 08/07/2013 Next Test Date: 16/07/2014 System Location: Titanium Based Alloys Alumina Oxide Assessment of System 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 however, there are actions required to monitor or improve the system. See readings and summary sections. Extraction Components / Specifications Extractor Manufacturer: JB Thorne Model: W185 Serial No: J34344/99 Fan Manufacturer: JB Thorne Fan Type: Centrifugal Drive Type: Direct Fan Serial No. Inlet Dia (m): Outlet Dia (m): r r QC 01 Motor Manufacturer: Motor (kw): 7.5 Motor (rpm): Prior to fan: Primary Filter Manu: N/A Description: Water Arrest System At Inlet: At Outlet: Across Filter: -415 Secondary Filter Manu: None Description: At Inlet: At Outlet: Across Filter: Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: r Model: 435/4 Rotating Vane: r Serial No: Hotwire: Calibration Date: 01/07/2013 Visual (smoke / lamp): r The system was tested under normal working conditions with a maximum of 6 point in use at any one time. Page 21 of 28 LEV046

27 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 22 of 28 LEV046

28 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 Additional Comments: There is good control of dusts when the hoods are correctly positioned around the wheels however, some escape could be observed at TP5 & TP6 as the hood is positioned very low. Good N/A Satisfactory Page 23 of 28 LEV046

29 Ref Test Point (TP) Duct size (m) Area (m²) Measured Guideline Flow rate (m3/h) Pressure (Pa) Measured Recommended Capture Capture Distance (m) Qualitative Test Verdict of Examination Examination Readings & Results Duct Reading Face Reading Results PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS Main Duct Reading Ref Dimensions Area Measured Recommended Flow rate Pressure (m) (m 2 ) (m 3 /h) (Pa) MD MD System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) 5235 N/A Summary The system was satisfactory at controlling the release of dust from the processes with performance in line with previous tests. Although the capture distance does not reach the release point at most hoods the hood is in the path of the released dust so aiding control. Recommendations Raise the hood TP5 & TP6 closer to the wheels to allow improved control of the released dusts. Page 24 of 28 LEV046

30 Report Reference: LEV Fan Airflow Rate. 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: 16/01/2014 Forge Side Blaenavon Tested by: A.Bawler Pontypool NP4 9XG Signature & Stamp Last Test Date: 14/11/2013 Next Test Date: 16/07/2014 System Location: Blade Polishing (DMS) LEV Process / Type: Linish & Polishing MC No. Extractor: JB Thorne W185 MC No. Released Substances To Be Controlled Dust Mist Fume Vapour Gas Titanium Based Alloys Alumina Oxide Assessment of System The system was found to be SATISFACTORY at controlling the hazardous substances however, there are actions required to monitor or improve the system. See readings and summary sections. Extraction Components / Specifications Extractor Manufacturer: JB Thorne Model: W185 Serial No: J35923/01 Fan Manufacturer: JB Thorne Fan Type: Centrifugal Drive Type: Direct Fan Serial No. Inlet Dia (m): Outlet Dia (m): r r QC 01 Motor Manufacturer: Motor (kw): 7.5 Motor (rpm): Prior to fan: Primary Filter Manu: N/A Description: Water Arrest System At Inlet: At Outlet: Across Filter: -174 Secondary Filter Manu: None Description: At Inlet: At Outlet: Across Filter: Test Conditions, Production, Environment and Equipment Used Make: Testo Pitot Static Tube: r Model: 435/4 Rotating Vane: r Serial No: Hotwire: Calibration Date: 01/07/2013 Visual (smoke / lamp): r The system was tested under normal working conditions with all points in use. Page 25 of 28 LEV047

31 Plant Photograph / Diagram Extraction unit discharge to atmosphere MD1 TP1 TP2 TP3 TP4 TP5 TP6 Extraction unit discharging direct to atmosphere TP1 TP2 TP4 TP3 TP5 TP6 Page 26 of 28 LEV047

32 Description of LEV system & Process A wet dust extraction unit is used to control the release of metallic dusts from a range of linish and polishing machines. The system consists of a main header duct with drops to the individual machines and final connections to the receptor /capture hoods at each process by the use of galvanised and flexible ducting. Fitted inline between the machines and the header duct are fire dampers to shut down the extraction in the event of a fire to prevent spread to the extraction unit. Each duct drop leads to a receptor hood which receives the dust from the grinding / polishing wheels, the hoods have an adjustable top section which is to be adjusted to surround the wheel to enclose the operating area and provide maximum available face capture distance and velocity. The system is fitted with an airflow indicator in the main header duct to monitor performance with a red / green section to indicate the health of the system. The extraction unit which uses water to arrest the dust and the residual air is discharged direct to atmosphere by a discharge duct exiting the adjacent wall. The system is designed and is capable of controlling the release of dust with all points open. LEV System Visual Examination Notes Discharge Termination: Motor Direction: Cleaning System: Airflow Indicators: Straight Duct Correct None Yes Discharge to: Filter Condition (Visual): Cleaning System Working: Airflow Indicators Working: To Atmosphere Good N/A Satisfactory Additional Comments: There is good control of dusts when the hoods are correctly positioned around the wheels. The fire damper on points TP3 & TP4 has a broken link causing partial closure of the duct, so reducing air flow rate. Page 27 of 28 LEV047

33 Ref Test Point (TP) Duct size (m) Area (m²) Measured Guideline Flow rate (m3/h) Pressure (Pa) Measured Recommended Capture Capture Distance (m) Qualitative Test Verdict of Examination Examination Readings & Results Duct Reading Face Reading Results PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS Main Duct Reading Ref Dimensions (m) Area (m 2 ) Measured Recommended Flow rate (m 3 /h) Pressure (Pa) MD System Performance Design / Initial Readings Latest Readings Flow Rate (m³/hr) Pa Latest Flow Rate (m³/hr) System Effectiveness (%) Summary There was good control at all points of the system, however there has been a drop in performance due to the fire damper on TP3 & TP4 operating and partially closing reducing air flow at this point and increasing the overall static pressure in the system. Although currently the air flows are still adequate at this point the damper needs to be replaced. Although the capture distance does not reach the release point at most hoods the hood is in the path of the released dust so aiding control Recommendations The fire damper on TP3 & TP4 needs to be replaced. Page 28 of 28 LEV047

34 4. Supporting Information Method of examination and test 1. Identification of the system is made to determine the process, what substances are being controlled and how the LEV is controlling the substance. 2. If the examination and test is a repeat test then reference is made to the initial appraisal and thorough examination and test of the system to determine the test points and base line figures for control of the substance. 3. A full examination and inspection of the system is conducted to ensure all parts of the system is performing as designed with no defective parts. 4. Using a hot wire, vane anemometer, pitot-static tube and manometer set, readings were taken on the extraction systems. 5. Where readings were taken in a duct, a pitot traverse is completed with a pitot-static tube and manometer, 6 airflow measurement readings were taken; the average reading was recorded. A static pressure reading was also taken at the same point. 6. Face velocities were taken by dividing the measured area into zones approx 150 x 150mm and a measurement taken in each zone; the average reading was recorded. Readings were taken using hotwire or rotating vane anemometer. 7. Where a face reading was taken at a capture hood which is away from the source the maximum distance was recorded at where the minimum recommended air velocity is achieve, in the report this is known as the capture distance. 8. Smoke and or lamp tests will be conducted where allowed to demonstrate the effectiveness of the extraction and the capture of contaminate. 9. Where a paint booth is tested a clearance time will be given which is the time taken to clear the booth of residue paint vapours after the operation is stopped, this is tested by a visual smoke test, method as stated by HSE Measuring Paint Spray Booth Clearance Time. 10. After each system measurement a digital photograph was taken to help identify the plant in the LEV certificate. 11. The reference points are then sealed ready for subsequent tests. Frequency of LEV Examination & Testing LEV Examination and Testing is required every 14 months unless otherwise stated in HSG258, as below: Process Processes in which blasting is carried out in or incidental to the cleaning of metal castings in connection with their manufacture Jute cloth manufacture Processes other than wet processes, in which metal articles (other than gold, platinum or iridium) are ground, abraded or polished using mechanical power, in any room for more than 12 hours per week. Processes giving off dust or fume in which non-ferrous metal castings are produced. Minimum Frequency 1 month 1 month 6 months 6 months Note: The above frequencies are a minimum. The certificate is only valid for the time period stated above if the result is satisfactory and the system is adequate at controlling the released substances. Where test points have unsatisfactory readings and are not adequate at controlling the released substance then the certificate or test point on the certificate is not valid and remedial action is required to the system to control the released substance. LEV Services Ltd. Vidanta, Lower Henlade, Taunton, Somerset TA3 5LY. Tel: info@levservices.co.uk

35 Recommended duct transfer and face capture velocities Recommended Average Face or Capture Velocities: Vapours/Gases: Dusts Dust Emitted are High Velocity: 0.25m/s to 0.5 m/s 0.5 m/s to 1.0 m/s 2.5 m/s to 10 m/s Recommended Average Duct Conveying Velocities: Vapours/Gases (Non Condensable): Vapours/Gases (Condensable): Light to Medium Density Dusts: Heavy Dusts: 5m/s 10 m/s 15 m/s 20 m/s to 25 m/s These are guidelines only, the actual required velocities could differ from the recommended, this could be due to recommendations in the initial appraisal and commission report of the LEV or from the LEV examiner where evidence is used to back up the change in the recommended velocity. Exposure Monitoring Tests The assessments that have been undertaken in this report do not necessarily guarantee that adequate control of exposure is being achieved. In certain instances, we recommend that exposure monitoring (air sampling) is undertaken to either prove or disprove the effectiveness of a system. Regular Inspection In addition to the thorough examination and testing described within this report it is necessary to conduct regular inspections and checks on the LEV systems. What form this inspection takes, and its frequency will depend upon the nature of the plant. The COSHH Approved Code of Practice recommends that weekly visual checks should be made to identify any previous defects. If the LEV controls a particularly hazardous substance then more frequent checks may be necessary. Plant operators need to know what to look for and how to report it. The regular inspections may include: Ensuring the LEV is always running when hazardous substances are being emitted or are likely to be emitted Observing the condition of the suction inlet such as hoods, booths etc to see whether it has moved or has been damaged Observing the condition of any visible ductwork and dampers by the inlet Observing any evidence of control failures, for example noticing if there are unusual dust deposits or a stronger odour than normal immediately outside the LEV Observing any local instrument that has been fitted to the LEV to show its performance, such as a pressure gauge on a filter or an airflow device on a fume cupboard Undertaking any minor servicing such as emptying filter bins. LEV Services Ltd. Vidanta, Lower Henlade, Taunton, Somerset TA3 5LY. Tel: info@levservices.co.uk

36 Regular Service & Maintenance A programme of regular maintenance for all the LEV systems should be instituted and suitable records should be kept. This should include checking, cleaning and replacing, where necessary, the following components: fans, motors, drives, filters, grilles, ductwork and control hoods. Airflow Indicators It is recommended by the HSE that airflow indicators are fitted to each hood within a LEV system, this helps show that the system is maintaining airflow and continuing to control the released substance. Where there is a change in performance this would be displayed on the airflow indicator device and maintenance / repairs performed to return the system to its original specification. Where fume is released at source and it is visual an airflow indicator may not be necessary as it is obvious if the fume deviates from the path to the control hood. The airflow indicators are very good where fine dusts and vapours are released and escape of the substance into the workplace would not be easily seen. Publications and additional information There are many HSE publications for employers and employees, we highly recommend that the HSE website is used, choose LEV (Local Exhaust Ventilation) under the topics drop down list which will take you to the guidance area, many guides are free to download. Two guides that are readily available: Clearing the Air A simple guide to buying and using LEV systems. Time to Clear the Air A workers pocket guide to LEV. These are recommended for distribution to departmental Managers that buy and use LEV equipment and that the pocket guides are handed out to employees. Reference documents HSG 258 COSHH Regulations 2002 (as amended) LEV Services Ltd. Vidanta, Lower Henlade, Taunton, Somerset TA3 5LY. Tel: info@levservices.co.uk