LEV Inspection & Test Report CLIENT: SITE: XXXXXXX LTD XXXXXXX Report Reference: Hinge Room-LEV System Identification: BeCu ESTA Survey Conducted By: Name: Position: Signed: XXXX Environmental Consultant Visit Date: 7 th December 2015 Issue Date: December 2015 Assessment of Level of Control Satisfactory
System: BeCu ESTA Executive Summary: At the request of Mr XXXX, Engineering Manager with XXXXX Ltd, XXXXX Ltd were contracted to conduct a thorough examination and test of the of the various Local Exhaust Ventilation (LEV) systems at the XXXXX Ltd production facility at XXXXX. Site works were undertaken on 7 th & 8 th December by XXXXX of XXXXX Ltd without supervision. XXXXX is an Environmental Consultant with XXXXX Ltd. This report covers the following system: BeCu ESTA, located within the Hinge Room The performance of the system was seen to be satisfactory; however a number of improvements are recommended. Fitting of air flow or pressure indicators to system to aid operators in confirming the system is performing satisfactorily Locating LEV logbook for system. Ensure logbook is filed in a suitable location accessible to all relevant parties Updating the method statement for the process to include operator pre-checks to LEV system prior to beginning the process
System: BeCu ESTA Introduction: The site comprises a purpose built facility for the manufacture and testing of components to be used in the aerospace industry. The site was originally established in the 1940 s and has undergone extensive expansion and modernisation since opening. The system is understood to have been installed in January 2015. initial report or LEV logbook for the system could be located; discussions with site indicate that that these records may currently be in storage while the engineering department is being relocated to a different area on site. The most recent test to the system was undertaken in June 2015; again this report could not be located at the time of survey. The LEV system is located in the ground floor Hinge Room and is designed to control Beryllium and copper dust/particulates and fume generated during the polishing, soldering and drilling of hinge plates for use on a number of products manufactured in other areas of the factory. It is understood that the system is normally in use approximately 10 to 15 hours per week. System of Work: Site induction and walk round of the area was conducted with the engineering manager. The XXXXX LEV testing risk assessment document for the Hinge Room was reviewed and seen not to require any amendments before works could start. A copy of this risk assessment is attached. It was not necessary to disable the fire alarm sounders during the survey. Findings and, recommendation resulting from the examination and test of the system were discussed with the engineering manager at the completion of the survey. Existing Records: LEV logbook could not be located Previous thorough examination and test report (June 2015) could not be located
System: BeCu ESTA LOCAL EXHAUST VENTILATION PLANT COSHH REG. 9 EXAMINATION AND TEST 1: Client: XXXXX 2: System ID: BeCu ESTA Location: Hinge Plate Room Process: Hinge Plate Manufacture (polishing and drilling) Initial thorough examination: 3: Assessment of Level of Control: 4: Interval Between Routine Examinations: LEV 1 Satisfactory LEV 2 Satisfactory 6 monthly 5: Date of Previous Examination and Test: June 2015 6: Hazard(s) to be Controlled: 7: Restrictions/Precautions: 8: Instruments Used & Ser.. Beryllium and copper Standard PPE Airflow LCA501 Vane dust/particulates and fume Safety Glasses anemometer Nitrile gloves S/N LCA501039017 Airflow Pitot tube TSI 8386 Manometer S/N 00030598 Testo 425 hot wire anemometer S/N 01425921 9: Summary Action Plan Item in LEV Action Required system 1 - LEV System Fit appropriate visual indictors to system to enable operator to confirm system is operating satisfactorily 2- LEV Logbook Locate system logbook and file in a suitable location. Ensure logbook is includes user manual for system, prevouis test reports etc 3-Process Ensure method statement for Method process includes operators Statement pre-check instructions for LEV system Priority * 2 2 Person to take action Target Date Examiner name Signature Client name Signature 2 Date Completed Date December 2015 *Priority e.g. 1 = high, 2 = medium, 3 = routine Examiner: green boxes Employer: yellow boxes I accept this report YES /NO Date
HOODS/ENCLOSURES System: BeCu ESTA 10:(a) Hood(s) Type/Description: LEV 1 - Partial enclosure booth LEV 2 Capture hood 10:(b) Visual Examination Report: Partial enclosure in a clean and satisfactory condition with no visible damage. Capture hood has mesh grill across face very slight deposits observed 11: Hood Sash or Face Velocity Capture Distance Hood Hood ID Open Area Opening ht. Actual Mean Measured Required Static Pressure Volumetric Flow Rate LEV 1 (Fume cupboard) m 2 m m/s m/s m m Pa m 3 /h 0.178 2.52, 2.76, 2.35 - - 1505.9 2.20, 2.26, 2.18, 2.15 LEV 2 (Capture hood) 0.00283 22.95, 21.50, 21.38, 24.65, 21.69 22.43 0.28 0.10 228.5 LEV 1 0.4 x 0.445m LEV 2 0.06m diameter 12: Date of Installation: January 2015 System Total Volume: m 3 /h 13:. of Hoods on System: 2 14: Process Conditions at Time of Test: Max. to be used at any time: 1 t in process 15:(a) Hood Static Pressure Gauges 15:(b) Hood Pass/Fail Stickers Fitted? Fitted? Yes 16: Qualitative Containment Test Report: Method Used: Smoke Release Smoke testing showed satisfactory smoke capture around the perimeter and across the face of partial enclosure LEV 1. Smoke testing of capture hood LEV 2 showed satisfactory smoke capture beyond the required minimum of 0.1m.
DUCTING System: BeCu ESTA 17:(a) Type/Description: G/S cylindrical dusting and 18: Visual Examination Report: plastic flexi-hose 17:(b) Air Temp in Ducts: TP1 22.2 o C; TP2 22.1 o C Ducting in good condition with no visible damage observed 17:(c) Barometric Pressure: 19: Diameter/ Test Dimension Point ID LEV 1 (T.P-01) Duct Area Static Pressure Velocity Pressures on Traverse Duct Velocity Actual Measured Mean Transport Velocity Duct Volume Flow (mm) (m 2 ) (Pa) (Pa) (m/s) (m/s) (m 3 /h) 140 0.0154-293 21.70, 21.20, 20.20, 20.40, 21.30, 21.90 21.12 1170.9 LEV 2 (T.P-02) 65 0.0033-301 20.00, 20.70, 20.40, 20.90, 21.30, 21.50 20.80 247.1 Hood volume data Total m 3 /h 20: Damper Settings: 21: Stack height (m) and Termination Type: Since prevouis test dampers now fitted to LEV1 and LEV2 to allow one hood to operate at a time. Testing conducted with LEV 1 damper open and LEV 2 damper closed and with LEV 2 damper open and LEV 1 damper closed 22: Fan Motor Data: 23: Filter/Air Cleaning Devices: Make/Model ESTA SRF K-10 FM Make/Model ESTA SRF K-10 FM N/A Type Centrifugal Type Volume Flow 950 (m 3 /h) Volume Flow Static Pressure P Drop Motor 230v / 1.3Kw Filter Media Carbon filter plus pleated cylindrical cloth filter Rating / Current 50Hz / 8.3A Filter Cleaning Annual service Motor Speed Variable Function Check Transmission Electrical Monitoring Gauges etc. - Operational Check Rotation Direction Correct anticlockwise Recirculation of Filtered Air? Yes
System: BeCu ESTA 24: Return of Exhaust Air to Workroom Filter Efficiency t assessed Measurement Technique Static Pressure at Inlet, Pa Estimate of concentration of contaminant in returned air Comments Recommendations and priority* t assessed t assessed ne ne * e.g. 1 = high, 2 = medium, 3 = routine 25: Make-up air Adequate quantity Yes Measurement Technique Induced draughts Comments Recommendations ne ne 26: Alarms Hood / enclosure Duct Air cleaner Air mover Returned air Comments Recommendations ne ne 27: Statement of System Performance Specification: Smoke testing of LEV 1 showed satisfactory smoke capture around the perimeter and across face of hood. Face velocities complied with the recommended 0.5m/s for this type of hood containment system. Duct velocities for LEV 1 ducting complied with the recommended ~20m/s for grinding dust. Smoke testing of LEV 2 showed satisfactory smoke capture up to 0.28m from the hood face beyond the required 0.1m minimum to point of process. Face velocities complied with the minimum 2.5m/s-10m/s required for these types of contaminant. Satisfactory protection provided to operators. Duct velocities ducting complied with the recommended ~20m/s guideline for this type of process contaminant. The filters to the system were examined and were seen to be in a clean and satisfactory condition
400mm System: BeCu ESTA 28 Schematic Drawing of System: BeCu ESTA G/S DUCT 140mm DIA Damper Damper BENCH TP01 ESTA FAN/ 445mm FILTER UNIT LEV 1 TP02 G/S DUCT 60mm DIA PLASTIC FLEXIHOSE 65mm DIA LEV 2 MINI PILLAR DRILL FACE 60mm DIA BENCH
System: BeCu ESTA 29 Inspection Photographs: Inspection Photographs LEV 1 LEV 2 New dampers fitted to system LEV fan / filter unit Filters seen to be in a clean and satisfactory condition Motor confirmed running in correct direction (anticlockwise)
System: BeCu ESTA 30: Conclusions Thorough examination and testing is currently undertaken every six months as required The inclusion of dampers in the system has improved the overall system performance Smoke release showed adequate contaminant capture for LEV1 and LEV 2 Duct velocities were seen to be above the recommended speed of 20m/s which will prevent the settlement of contaminant in the system duct work Currently no monitoring equipment fitted to system to aid operator in confirming the system is operating satisfactorily. Hoods, filters and duct work were inspected and were seen to be in a clean and satisfactory condition. LEV logbook could be located at the time of the visit. It is understood that the folder may currently be in storage due to the relocation of the engineering department. It is a requirement that all LEV systems have a logbook so as to keep a record of regular examination, maintenance and repair activities to the system. The log book should be kept in a location where it can be easily accessed by all relevant parties involved in the operation, examination and maintenance of the LEV system. The logbook should contain the following: Schedules for regular examination and maintenance of the system Records of examination of the system Records of any maintenance activities carried out to the system and if applicable any repairs or modifications undertaken to the system Checks of compliance with the correct way of working with / operating the LEV System including sign off signature by person undertaking the checks The method statement for the process was reviewed and was seen not to include any information on prechecks the operator should undertake to the LEV system prior to starting the process. June 2015 thorough examination and test report could not be located 31: Recommendations Fit appropriate air flow or pressure indicators to the system to enable operators to confirm system is operating satisfactory. Ensure operators are adequately trained in reading of indicators and aware of what values show the system is operating unsatisfactory. Locate LEV log book for system and file in an easily accessible area for use by all relevant parties involved with the LEV system. Ensure book contains examination, maintenance and repair schedules and records for the LEV system. Locate June 2015 report and file in the LEV logbook. If report be located cannot contact XXXXXX Ltd client support for the issue of a replacement report.
Pre Inspection Risk Assessment: XXXXX Ltd Client XXXXXX Ltd Address XXXXXX Department Hinge Room Hazard Applies Risk Control and Precautions Further Action Required Exposure to hazardous Yes Low risk. Follow procedures given in substances in Hinge Room Client requested to ensure method statement and processes, where practicable, are not taking place during LEV examination and test COSHH guidelines. awareness Disposable overalls/ppe should be worn to protect normal clothing, where necessary. XXX Engineers fully trained in COSHH awareness procedures. Electrical hazards Yes Low Risk. Access not required to areas of equipment/machinery containing live electrics All testing equipment uses low voltage batteries. Access and egress to Yes Low Risk: working area XXX Engineers made aware of client policy on access and egress during site induction. Chemical hazards Yes Low Risk: hazardous chemicals are used during survey but these may be present in the area of work. Appropriate PPE to be worn where necessary. XXX Engineers receive COSHH awareness training. ise Yes Low Risk: Process does not create significant noise level ise created by survey activities is unlikely to be significant. Ear protection available if required to control noise exposure from plant activities. ne If engineer deems access unsafe the task shall be halted and the Engineering Manager informed Check with client before commencing work if other activities in area create significant hazard. If so, follow specified precautions given in client s COSHH assessment. Check with client before commencing work if other activities in area create significant noise hazard. If so, follow specified precautions given in client s noise assessment. ise meters and trained operators are available to carry out monitoring if required. XXX Engineers receive noise awareness training
Manual handling Yes Low Risk: Survey tools and equipment are lightweight. Stepladders and ladders are suitable for carrying by one person unaided. Moving of plant or manufactured items to be undertaken by XXXXX Ltd employees Manual handling awareness training provided to XXX Engineers Mechanical Low Risk: machinery to be operated, with the exception of the LEV, during the examination and test. ne. LEV to be isolated during examination of filters. Test of fan direction to be undertaken by site engineer Fire Yes Low Risk: Follow site fire safety rules. Cuts from sharp edges Yes Low Risk: Moving of plant or manufactured items to be undertaken by XXXXX Ltd employees Appropriate PPE to be worn where necessary. Slips, Trips and Falls Yes Low Risk: XXXXX Ltd policy for all production areas to be kept clean and tidy Check location of fire exits and escape routes before commencing work. Be aware of the risk of sharp edges, etc being present in survey area Engineering Manager to be informed if poor housekeeping observed Assessment prepared Name XXX Date: 07/12/15 by: Signature Survey Team Name XXX Date: 07/12/15 Signature Before carrying out any task the engineer shall carry out a last minute risk assessment. Any hazards observed should be recorded overleaf
Last Minute Risk Assessment Hazard Applies Risk Control and Precautions Further Action Required Review/ Amendment by: Name Date: Signature