How do you control welding fumes?

Use alternative cold joining techniques

Weld in ways that produce less fumes

Local exhaust ventilation (LEV)

Use PPE including welding clothing and RPE to prevent inhalation of fumes and gases

maintain control measures and general ventilation

Ascertain that welders are aware of the dangers and how to apply controls

According to the HSE, when should LEV (Local Exhaust Ventilation) be used?

Welding on a bench or in a screened off area, moderate to high volume MIG/MAG production welding, small or medium-sized parts

Welding carbon and mild steels, as well as aluminium

TIG welding on stainless steels or aluminium in high-volume manufacturing

MIG, MAG, Flux cored, or MMA welding of stainless steels for stick welding

Air gouging in the form of arcs

Welding or slicing galvanised metal with a hot knife are both options (e.g. zinc plated)

Materials containing cadmium that have been welded or hot cut, and that have been painted with lead or chromate paints

LEV extraction is required for automated flame or plasma cutting, however this is normally built-in.

Resistance welding devices with several heads that are automated

What factors should you think about when buying a welding fume extractor?

Make sure the unit's capacity is sufficient. An operational flow rate of 1480 M3/hr will do just fine when removing fumes at source. Make sure the filter is adequate; many manufacturers use lower-quality filters to save money; a sophisticated E12 Hepa filter eliminates 99.5 percent of fumes. Avoid MDF Hepa filters; strangely, many well-known manufacturers are still utilising these old Hepa filters since they are cheap to produce. However, their proclivity for burning has resulted in major occupational safety hazards, so make sure to examine the cost of new filters. Furthermore, low-cost extractors are sometimes accompanied with exorbitantly priced replacement filters.

What are the consequences of failing to use fume extraction & dust extraction systems?

Lung cancer, chronic obstructive pulmonary disease (COPD), occupational asthma, welder's lung, and inflammation of the throat and lungs are all at an increased risk.

How does a welding fume extractor work?

Welding and grinding can create harmful fumes and gases, which are pulled into a cleaning system, which removes poisonous gases and prevents inhalation.

What is local exhaust ventilation (LEV)?

It's a ventilation system that prevents inhalation by removing airborne contaminants from the workplace, such as dust, mists, gases, vapour, or fumes.

Local exhaust ventilation (LEV) for welding

When set up and operated appropriately, on-torch fume control is the most effective fume control for MIG welding. Use LEV with a mobile fume collection cowl for various forms of welding fume when on-torch isn't an option. Make sure it's set up correctly so it may be utilised without jeopardising the weld's integrity.

On-torch extraction is effective because

It's built into the welding gun, travels with the weld, stays near to the fume source at all times, and doesn't rely on the welder to relocate the extraction gun to keep fumes contained.

Extraction directly at welding torch

The torch connects simply to the appropriate device for catching the majority of harmful gases. The extractor is immediately positioned on the welding flame, ensuring continual access, work freedom, and a high capture rate.

Extraction with extractor arms

The arms are attached to a vacuum filter system that removes airborne pollutants. The extraction arms are flexible, easy to place, and do not block the welder throughout the welding process. The welding process is unaffected, and the capture rate is excellent.

Portable fume extractors/filter units

The extractor arm may be easily positioned anywhere in the workshop. When welding is done in a variety of locations, a portable solution is optimal. They are flexible, easy to position, and do not block the welding process in the same way as fixed extraction arms do.

Industrial welding and grinding table

The tables feature integrated gas, dust, and particle extraction during welding, grinding, and polishing. It's ideal for fixed workstations because it completely covers the table's surface area. The extraction point does not need to be adjusted, and the capture rate is great.

Fume extraction for welding robots

Nozzles may be directly attached to a welding machine, safeguarding both essential electronics and facility staff. An extractor fixed on the welding nozzle or a cover put over the robot are two choices for this technology, both of which have a high catch rate.

What sorts of welding fume extractors are there?

Portable

On-Torch Packages

Mobile

Wall Mounted

Multi-User Systems

Downdraft Benches

Robotic Applications

Systems for Colleges & Training Centres

When welding, fumes, gases, dust, and particles can cause health problems

Cancer e.g. lung, liver, kidney, eye, bowel, intestine

Acute pneumonia, COPD, and siderosis are just a few related lung conditions

Occupational asthma, acute irritant-induced asthma

Neurological conditions such as Alzheimer's and Parkinson's

Heart disease

Infertility

Metal fume fever

Asphyxiation

Ulcers

Allergies e.g., dermatitis

What’s involved in an LEV inspection?

To begin, the extraction unit, hose, nozzle, hood, arms, and filters are checked for faults or possible concerns in order to maintain the equipment's correct performance and safety. Also, check the extractor hoods for cleanliness and, if there are any moving components, make sure they're still working. Is the information provided by the monitor and airflow indicator accurate and corresponds to the inspector's measurements? Is the extractor leaking fumes, and if so, is the equipment properly treating the vapours to safeguard employees and bystanders? Is there an alarm system in place, and if so, does it sound when it's not working properly, such as when there's a blockage, to alert you to a performance issue? Is there a filter warning light that illuminates when the filter becomes clogged?

The extractor's report follows, which includes machine information, location, customer information, time, date, test kinds, and equipment utilised.

 Comparing the test results to the benchmark performance, calculating the exact numerical results of each working part, determining whether each test passed or failed, and determining the inspection result. Repairs or replacements are recommended for deteriorating components.

What’s checked in an LEV inspection?

Check for damage

Suitable operation of mechanical parts

Is there water damage

Are there blockages

Visual examination of all parts and components

Efficiency of filters

Extraction methods

Extraction using on-torch fume extraction, it is the most efficient fume control for MIG welding because it eliminates the majority of dangerous gases at the source if utilised appropriately without sacrificing weld integrity. Traditional fume extraction arms can't reach welds all welds, but on-torch fume extraction arms can.

Fumes are extracted immediately above the welding pool using a welding torch with fume extraction connected to the tip of the flame. Toxic gases are expelled through an opening in the nozzle at the end of the torch while welding. The vapours are suctioned via the torch, treated, and filtered in the collector before being safely evacuated.

Multi-user extraction

Multi-user extractors may be more efficient and cost effective than individual extractors in workplaces with several welders, workstations, or welding equipment. They may be tailored to match the wants and requirements of businesses.

Mobile fume extractors

Mobile fume extractors are suited for at-source extraction in heavy welding operations, with the added benefit of mobility inside the workplace. Mobile extractors are light enough to move around the work area and include wheels, a big extraction nozzle, and hose.

Extraction arms

Extraction arms may be fastened and affixed to walls, making them perfect for small workshops or workstations. Because of their excellent manoeuvrability and stability, they are simple to operate, modify, and carry. The MasterWeld extraction arms are heavy-duty and may be used to weld huge things as well as tiny to medium-sized products.

Key performance indicators of fume extraction

Filter pressure

As a result of additional cleaning cycles, the greater the filter pressure, the more power and emissions are produced. To get the decisive airflow performance, differential pressure is used to assess the quality of filter cleaning and filter life expectancy.

Duct pressure

The pressure in the ducts and hoods may be checked to ensure that the airflow is enough and the extractor is operating properly to guarantee proper extraction of fumes, gases, dust, and particles from the working environment and to give clean air.

Filter cleaning pressure

Filter cleaning at too high a pressure might damage the filters, require more power, and be noisier than necessary. However, if the pressure isn't high enough, the filter won't be cleaned thoroughly, and the life cycle will be shortened as a result of the decreased cleaning efficacy. Furthermore, the need to clean more regularly wastes more energy and leads to increased wear over time.

Smart filters

Welding fume extractors with smart filters detect and monitor, which enhances planning, reduces the need for planning, and lowers maintenance costs. Smart filters may assist experts in predicting mistakes and detecting difficulties early, resulting in a longer life cycle, reduced energy usage, increased safety, and a lower risk of fire due to failure. Professionals can also make great judgments quickly and productively because to its intelligence.

Dust bin leve

Cleaning and disposal of the dust bin contents, which accumulates over time, is a common welding fume extractor maintenance task. Warning lights can save time and prevent bins from getting overfilled by reducing the amount of time spent monitoring several bins that aren't full.

Fan performance

A variable frequency drive, which is popular in extractors, can provide technical information on the motor's life cycle and performance. The fan should be inspected on a regular basis since it consumes the most energy and adds to the fan's longevity. Maintenance can help prevent problems, and responding quickly when problems arise, such as vibrations, can help protect the motor from damage.

Extraction hoods

Workers may be exposed to welding fumes if they are not appropriately positioned

There should be no obstructions in the work area

Smart extraction hoods may boost productivity and save costs

They should never be used in place of ventilation hoods

It's not possible to remove shielding gas

It's vital to plan the dimensions before installing arm extractors

If the extraction hose is too distorted, airflow may be reduced

Using fume extraction arms to collect dust and fume

Extraction arms cannot be used to remove settled dust and odours in the same way as vacuum cleaners can. They're also not the finest choice for dust removal during cutting and grinding; extraction tables are the best option.

Benefits of capturing welding fume at source

Fumes can be caught, cleansed, and expelled more cost effectively in industrial or workshop utilities due to smaller equipment such as nozzles, hoses, fans, and motors. Capturing welding fume at the source eliminates virtually all of the hazardous welding fume to welders and onlookers, restricting particles that drop on the ground, work tables, items, and machines, and thereby reducing cleaning time. In principle, machinery that is shielded from on-site extraction requires less maintenance, extending its life cycle.

High and low fume extraction

This is determined by the quantity of space available in the work area and the welding procedures used. Low vacuum extraction arms can be over 16 feet long, and contorting extraction hoses can reduce their efficacy. Work places must have enough of room above head height and surrounding the workshop to successfully install them. If you need to be able to transfer your extraction gear, a portable welding fume extractor or on-torch extraction would be the ideal option. On-torch extraction may be the best option in work locations with restricted workspace.