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NSVWS Fm-89
An American National Standard-/ -
ANSVAWS F3.1-89
An American National Standard
Approved by
American National Standards Institute
June 12, 1989
Guide
for
Welding Fume Control
Prepared by
Abstract
This document introduces the reader to various types of ventilation systems, including dilution and local
exhaust, for control of welding fume. It contains health hazard information on air contaminants found in the
fume, sample design calculations, and drawings that illustrate ventilation techniques.
AWS F 3 * 1 8 9 M 0 7 8 4 2 6 5 0005967 5
Personnel
AWS Committee on Ventilation
W. Cheney, Chairman
A. H. Krieg, 1st Vice Chairman
J. Ashe, 2nd Vice Chairman
M. E. Kennebeck, Secretary
W. J. Astleford*
A. Ditschun *
W.H. Drake, Jr.*
C. A . Dupraz*
P. S.Eshelman
J. E. Glander
R. H. Keith
G. Mosher
H. Van Wagenen
AWS F3.L
87
07842b5 0005769 7 W
Foreword
(This Foreword is not a part of ANSIIAWS F3.1-89, Guide for Welding Fume Control, but is included for
information purposes only.)
In 1981, the American Welding Society entered into an informal arrangement to distribute an insurance
company publication Welding Fume Control with Mechanical Ventilation. In October, 1986, the copyright
was purchased and an updated version was prepared for publication as an AWS document. This document
contains information to help plan new or evaluate existing systems for control of welding fume in the
workplace.
Comments and inquiries concerning this specification are welcome. They should be sent to the Technical Director,
American Welding Society, 550 N.W. LeJeune Road, P.O. Box 351040, Miami, Florida 33135.
iv
COPYRIGHT American Welding Society, Inc.
Licensed by Information Handling Services
Table of Contents
Page No
.................................................................................
..................................................................................
............................................................................
1. Scope., ................................................................................
2. Welding Fume Hazards ..................................................................
2.1 Types of Contaminants .............................................................
2.2 Overexposures .....................................................................
3. General and Dilution Ventilation ..........................................................
3.1 General Ventilation .................................................................
3.2 Dilution Ventilation .................................................................
4 . Local Exhaust Ventilation Control ........................................................
4.1 General ...........................................................................
4.2 Equipment ........................................................................
5. Local Exhaust ventilation Design Procedure ................................................
5.1 Procedure and Phases ...............................................................
5.2 Exhaust Subsystems ................................................................
5.3 Minimum Air Velocities .............................................................
5.4 System Sizing ......................................................................
5.5 System Balancing ...................................................................
5.6 System Design .....................................................................
5.7 Example Calculations ...............................................................
6. Local Exhaust Ventilation Equipment ......................................................
6.1 Freely Suspended Hoods ............................................................
6.2 Crossdraft Table ...................................................................
6.3 Downdraft Table ...................................................................
6.4 Enclosing Hood ....................................................................
6.5 Open Hood ........................................................................
6.6 Gun-Mounted Exhaust Hood ........................................................
Personnel
Foreword
List of Figures
iii
iv
vii
1
1
1
1
1
1
1
2
2
2
2
2
3
3
3
3
4
4
5
5
5
5
8
8
8
AWS F 3 - 1 89
0 7 8 4 2 b 5 0005971 7
......................................
........................................................................
............................................................
........................
............................................................
..............................................................
...................................................................
...................................................................
.........................................................
....................................................
.............................................................................
9. Respiratory Protection ...................................................................
10. References .............................................................................
8 Ventilation System Evaluation
8.1 Basic Relationships: Air Velocity. Pressure and Volume Flow Rate
8.2 Testing and Maintenance
8.3 Static Pressure Analysis
8.4 Fan Performance
8.5 Fan Horsepower
8.6 System Evaluation Summary
8.7 Ventilation Evaluation Equipment
8.8 Safety
vi
COPYRIGHT American Welding Society, Inc.
Licensed by Information Handling Services
9
9
10
15
15
15
16
17
17
18
18
18
18
18
~~
List of Figures
Page No
Figure
.
Duct Friction Loss .....................................................................
- Elbow PressureLoss ...................................................................
- Branch Duct Entry Pressure Loss ........................................................
4 - Freely-Suspended Open Hood ...........................................................
5 - Movable Exhaust Fume Hood ...........................................................
1
2
3
......................................................................
......................................................................
........................................................................
..............................................
........................................................
............................................................................
6 - Crossdraft Table
7 - Downdraft Table
8 - Enclosing Hood
9 - Open Hood with Welding Operation at Face
10 - Hood Mounted on Welding Gun
11 - Pitot Tube
6
8
8
9
10
11
12
13
14
14
16
vii
COPYRIGHT American Welding Society, Inc.
Licensed by Information Handling Services
1. Scope
This guide outlines recommended ventilation systems for the removal of welding fume from the workplace air. it is not intended as a comprehensivedesign
manual.
3.1 General Ventilation. General ventilation is ventilation by the general movement of air within rooms
and buildings. It may be by natural ventilation or
mechanical ventilation. Natural ventilation is air
movement from external winds, drafts from chimneys, or room thermal convection. Mechanical ventilation is provided by means such as fans and exhausts
that are provided for comfort purposes, and includes
local exhaust, local forced, and general area mechanical air movement.
AWS F 3 . L
89
= 0784265
0005974 2 W
Procedure
5.1 Procedure and Phases. Design procedure follows
a typical problem solving approach of recognizing
the problem, identifying possible causes, choosing
alternative courses of action, and carrying out the
action chosen.
5.1.1 Phase I: Analysis. When the amount and
kind of contaminants from fumes, vapor, or dust
have been identified as a health hazard, the designer
or person generating system requirements gathers
preliminary data consisting of the following:
(1) Layout of operations and workroom
(2) Preliminary line sketch of ductwork elevations
and horizontal layout, locations of hoods, fan, and
dust collector
(3) Rough design or sketch of recommended hood
with the required exhaust ductwork layout
(4) Information on the physical shape of the work
pieces, distribution of the contaminant generated,
and the toxicity of materials from each operation
( 5 ) Assigning a number or letter to each hood,
exhaust duct branch beginnings, endings, junctions;
each section of main duct; location and type of all
elbows and entries
(6) Selecting a method to control the discharge of
captured contaminant to meet interior or exterior air
quality standards
5.1.2 Phase II: Component Design. The preliminary information generated in Phase I should be sufficient to allow the following:
(1) selection or design of a hood for each contaminant source location
(2) determination of required exhaust air volume
rates
(3) determination of air velocities needed to capture the contaminant and move it through the
exhaust duct system
(4) determination of hood entry loss coefficients
5.1.3 Phase III: System Design. The information
fro-m Phases I and II is used to size the local exhaust
AWS F3.1 89
0 7 8 4 2 b 5 0005776 6
and amount of the airborne contaminants, the following general design procedure should be followed:
(1) Start at the hood farthest from the fan.
(2) Select or design the exhaust hood to capture
the contaminant at its source.
(3) Calculate the desired air volume and the minimum air duct velocity. Then use these values to determine the branch duct diameter.
(4) Determine the actual length of the ductwork
required from the layouts of operations and line
sketch of ductwork elevations and horizontal paths
developed in Phase A. Determine the equivalent
lengths of elbows and special fittings from reference
tables. The equivalent lengths of elbows and other
fittings are added to the various duct lengths during
the calculation procedure described later,
The Velocity Pressure Method has several advantages over the Equivalent Length Method of duct
design. It is generally faster and has the advantage of
allowing quick recalculation of branch duct sizes for
balancing the static pressures at duct junctions. The
Velocity Pressure Method is based on all of the frictional and dynamic losses in exhaust ducts and hoods
being directly proportional to the Velocity Pressure.
Loss factors for hoods, straight ducts, elbows,
branch entries, weather caps, and many other fittings
400 FM
= 2037 ft/min
(fpm)
= 4005 (VP)/Z
6.2 Crossdraft Table. The crossdraft table is a welding bench with a slotted exhaust on the side opposite
from the welder. The minimum exhaust volume
through the hood is in accordance with the formula:
as 0.55.
Q = KLWV,
AWS F 3 - L 8 7 9 07842b5 0 0 0 5 7 7 8 T W
.C
1ooO'
900
800
700
600
500
400
300
200
100
90
80
70
60
50
40
30
20
10
o1
.o15
.o2
.O3
.O4
.O5
.O6
.O8
.10
-15
.2c
2oo00
8000 -
loo00
6000
5000
4Ooo-
3000
1000
AWS F3.L
87
078Lt2b5 0005780 8
8
1 5 O MAX
-c
ROUND ELBOWS
I
I
R, NO OF
DIAMETERS
LOSS FRACTION
OF VP
2.75 D
0.26
2.50 D
2.25 D
2.00 D
1.75 D
1.50 D
0.22
1.25 D
ANGLE
DEGREES
0.26
0.27
0.32
0.39
0.55
20
25
30
35
40
45
LOSS FRACTION
OF VP IN BRANCH
0.12
0.15
0.18
0.21
0.25
0.28
60
0.32
0.44
90
1 .o0
50
WELDING BENCH
BASE METAL
RECTANGULAR HOOD PERFORMANCE FOR SHIELDED MANUAL
METAL ARC WELDING USING HOOD DESIGN IN FIGURE 4
V, (fpm) AT DISTANCE x = 18 in.
Q (CFM) VOLUME OF AIR FLOW
V (fpm) AIR VELOCITY AT FACE
VP (in. W. GAGE) VEL. PRESSURE, FACE
V IN DUCT (fprn)
VP IN DUCT (in. W. GAGE)
(25 Vp + 1 VP) x VPDUCT
S
,P
H
,
CARBON
STEEL
STAINLEE
50
919
460
.o1
1316
.11
0.14
STEEL
100
1838
919
.O5
2632
A3
0.54
duct layout. For this example, use a single slot variation of the welding bench, Figure 6, which gives the
hood entry loss as:
Hood Entry Loss, or
h, = 1.78VP slot
+ 0.25 VP duct.
AWS F 3 . 2
87
07BL12b5 0005782
L M
10
EXHAUST
THROUGH
AIR CLEANER
WHEN AIR IS
RECIRCULATED
AJ
WELDING ROD
I-I
U
~~
up to 6
6-9
9-12
335
755
1335
EXHAUST DUCT
EXHAUST HOOD
WITH SLOTTED
FACE (TYPICALLY 2)
HOOD LENGTH
BENCH WIDTH
DUCT VELOCITY
SF,
WELDING TABLE
=
=
=
=
AWS F 3 . 1 87
0 7 8 4 2 6 5 000578Li 5
12
EXHAUST DUCTS
7
l
OF TABLE
LSLOITED
BAFFLE-SIZE SLOTS FOR zoo0 fpm
DUCT VELOCITY = 2000 fpm MINIMUM
Q=AXV,
Q =
A =
V, =
h, =
13
EXHAUST DUCT
---y
FACE OREN
Q=AV,
Q = EXHAUST VOLUME, cfm
A = HOOD FACE AREA, sq. ft
V,
MINIMUM FACE VELOCITY, fpm
he = 178 VPsLorTO .25 VPovcr
DUCT VELOCIW = 3000 fpm MINIMUM
7,
w
2q
-
AWS F 3 - I J 8 7
0784265 000578b 7
'
14
WELDING OR CUiliNG TORCH
OR THERMAL SPRAYING GUN
C = A V ,
O
A
VI
ENTRY LOSS
h,
=
=
=
=
=
WELDING ROD
SHIELDING GAS
>p
INLET DUCT
EXHAUST
OUTLET DUCT
WORK
15
AWS F 3 - L 89 H 078qZb5 0 0 0 5 9 8 8 2
16
fr
SECTION ENLARGED ro
SHOW DETAIL
points across the duct diameter to determine the average velocity. This is done by making two traverses
perpendicular to each other with a Pitot tube to
obtain calculated average pressures. The measured
velocity pressures (VP) are converted to airflow
velocities. The velocities are then averaged. (Do not
average the V P and convert this to an erroneous average velocity.)
8.3 Static Pressure Analysis, When something happens to a ventilation system such as a loose fan belt
or partial plugging of a duct, the hood draws less air.
This is readily checked by measuring the static pressure with a manometer gauge. The rate of air flow is
directly proportional to the square root of hood
static pressure.
The static pressure in the hood is best measured in
the exhaust duct approximately one duct diameter
away from the hood. The hole in the duct for measuring static pressure (SP) with a manometer must be
smooth on the interior of the duct. Any burrs or
protruding edges cause turbulent air flow and results
in erroneous readings.
Measurements at other points in ductwork on
either side of the fan and air cleaners, or near branch
junctions, should be made several diameters away
from turbulent areas. Design SPs may be obtained
from system plans, or estimated.
The following examples indicate how static pressure (SP) tests can help diagnose problems:
(1) If hood static pressure (SP) is low on all hoods
but high between fan and air cleaner, then the air
:leaner should be checked.
(2) If hood SP readings are low on all hoods but
readings on both sides of the air cleaner are above
normal, then the main duct or branch duct may be
partially plugged (if air cleaner is ahead of fan).
(3) If the hood SP readings are low and also the
SP on both sides of the air cleaner are low, then one
of the following may exist:
(a) fan is not working properly
(b) discharge stack is plugged
(c) duct joint may be loose
(4) If all SP readings are normal except that one
hood SP is low, the branch duct between the low SP
readings and the main duct may be plugged.
( 5 ) If all SP readings are normal except one hood
SP is high, a blockage probably exists between the
hood opening and the SP test location.
(6) If all SP readings are near normal except SP
readings in two adjacent hoods are low, then the
main duct is probably plugged near the two hoods
with low SP readings.
8.4 Fan Performance. Fans do not need much attention except for periodic maintenance as long as the
system is operating properly. If power consumption
is higher than it should be, if decreased airflow
through hoods is attributed to poor fan performance,
or if additions to the ventilation system are being
considered, tests of fan performance may be
necessary.
Fan performance can be seriously affected by spinning airflow at the fan inlet. Fans are rated by the
manufacturer assuming that the air entering the fan
is moving in a straight line. If an elbow or other
disturbance causes spinning airflow, the fan will not
perform as expected.
One way to detect spinning flow is with a Pitot
tube. Insert the tube into the duct near the fan and
rotate it slowly up and down, and back and forth at
different points within the duct. The maximum
velocity pressure reading occurs when the Pitot tube
is facing directly into the air stream. If maximum
readings are found with the Pitot tube pointed
slightly upward on one side of the duct and downward on the other side of the duct, the approximate
angle of spin can be estimated. Retest the system
after flow straighteners or elbow turning vanes have
been installed to see if the condition has been
corrected.
Before working around a fan, review and be careful of the following conditions:
(1) Air blasts from fan outlets or exhaust stacks
can cause injury.
(2) Do not open fan access doors while the system
is running. On the fan outlet side, the doors could
open with explosive force.
(3) Close all access doors before starting the fan
motor. An open door on the suction side of the fan
can overload the motor during starting as well as
creating a suction hazard.
(4) If a fan motor belt drive guard must be
removed to measure rotating speed, beware of entangling long hair, ties, etc. in rotating machinery.
( 5 ) Whenever the fan is operated with a guard
removed or ducts disconnected, clear the area of
unauthorized personnel and post signs or guards to
keep bystanders away.
A fan rating curve obtained from the manufacturer for the model and size of fan at the installed
operating speed and air density will help in determining if the fan is operating in the desired range, or
indicate what corrective changes can be made,
A good fan test begins with a pitot traverse of a
straight duct section near the inlet to find duct velocity and airflow into the fan, Fan inlet velocity is
QxTP
6356 x ME
AWS F 3 - 1 87
0784265 0005770 O
18
9. Respiratory Protection
In cases where ventilation or hooding are not adequate to reduce contaminant concentrations to levels
that meet existing standards, refer to ANSI 288.2,
Practicesfor Respiratory Protection, for guidance on
selection and use of respirators.
10. References
(1) American Conference of Governmental Indus-