Dust particles generated in a wide range of manufacturing and production processes pose a significant hazard to health. They can cause respiratory diseases, skin irritation and eye problems, and, in some instances, can result in deadly explosions if left to accumulate in the atmosphere.
Effective control measures play a vital role in protecting people from the effects of inhaling contaminated air and should always be designed, installed and maintained by industry professionals.
Filtermist has over 55 years’ experience in ensuring workshop air is clean and safe to breathe. Global Commercial Director, Graeme Bell, and Field Engineering Manager Rob Fullwood, discuss the importance of working with professionals with specialist expertise.
Extraction System Specification
“Regulations including COSHH (Control of Substances Hazardous to Health) and DSEAR (Dangerous Substances and Explosive Atmospheres Regulations 2002) require exposure to hazardous, potentially explosive substances to be prevented or minimised as much as possible,” says Graeme.
“The best way to do this is by installing an LEV system to extract and filter contaminated air at source – this approach protects operatives by ensuring that the hazardous substance does not enter workplace air.
“From the outset, it is vital to establish exactly what substances need removing. If the substance is classified as explosive, such as flour or aluminum dust, ATEX rated explosion relief panels should be incorporated into the design of the LEV system. This can have implications on the position of the filtration unit - ideally the unit should be located outside so that in the event of an explosion occurring, the blast is outside away from works personnel, rather than inside, the factory.
“However, when this isn’t possible effective suppression systems should be incorporated into the system design.”
Explosion relief panels are also a consideration for Filtermist’s LEV engineers during routine LEV Tests, as Rob explains, “We carry out a comprehensive risk assessment as part of all LEV Tests and if this shows that the system is being used to extract potentially explosive substances, we will check to make sure ATEX rated panels are in use.
“If they are missing, we will include a recommendation that they need installing immediately in the report submitted to the customer. We strongly advise that all of our recommendations are acted on, but in hazardous environments this is even more important as it can literally mean the difference between life and death.”
Correct design of all dust control systems is key as Graeme explains, “We provide customised systems depending on specific client requirements and will select which dust filter is used depending on the characteristics of the dust that needs extracting.
"We manufacture own own range of dry dust extraction units and wet dust collectors under the Dustcheck brand and as part of Absolent Air Care Group, we also offer Absolent branded dust extraction units including the AD range which includes models suitable for use in ATEX Dust Zone 22.
“As well as vented explosion relief panels, certified ATEX equipment including anti-static filter bags, earth bonds, and non-sparking components can all be used to handle potentially explosive particulate. Explosion isolation valves and possibly fire dampers should also be incorporated into the ducting to prevent propagation of explosions or fire spreading in the event of an incident.
“We consider all aspects before recommending specific dust extraction LEV system components.”
Stand-alone or central extraction system?
Another important factor when it comes to system design is whether a stand-alone filtration unit, or a centralised system drawing contaminated air from multiple pick-up points would be more effective. “Again, this depends on the specific circumstances surrounding the job,” says Graeme. “The type and volume of contaminant, the number of extraction points required, available space, and budget will all have an impact on the final recommendation.”
Legal requirements
“Up to date knowledge of all relevant legislation is also key,” continues Graeme. “As well as a thorough working knowledge of regulations designed to control indoor air quality, if the extraction system is being vented outside, pollution prevention and control considerations must also be taken into account.”
Performance monitoring
Once the extraction system has been installed, it is then the responsibility of the employer to ensure it consistently performs as intended. COSHH regulation 9.2 requires most LEV systems to be tested by a competent person at least once every 14 months.
“The engineer will use a variety of equipment including a rotating vane anemometer or a hot wire anemometer to measure velocity at the test point, and a pitot tube to test pressure. Readings will then be compared with data in the system’s design specification and used as a benchmark to ensure performance is being maintained,” Rob comments.
As well as employers’ responsibilities under COSHH regulations, employees are also required to play their part in safeguarding the workforce. Operatives are required to report ‘forthwith’ any defects in the LEV system which could impact on its ability to work as intended.
Rob elaborates on how this requirement can be achieved; “There are a number of ways of checking that an LEV system is working correctly between routine LEV Tests. Daily checks should be carried out to look for any obvious signs of wear and tear, or indications that there may be contamination in the air.
“Pressure gauges and airflow indicators can be used to clearly identify pressure drops or other potential issues with the system. Using a dust lamp makes it easy to see airborne particulate, as well as checking that the fan is drawing the contaminated air into the filtration system.
“Smoke sticks can also be used to check the direction of extraction. Observations and data should be recorded in a log-book which can be used as an auditable trail in the event of any issues with the LEV system.”
Air monitoring
Air monitoring is designed to ensure control measures are working as intended and employees are breathing air which is clean and safe. “Static monitoring can be used to assess air quality in a specific area, whilst personal monitoring samples air in the operator’s breathing zone,” says Rob. “The results are then compiled into a report which can be used to help employers ensure they are compliant with current legislation and fulfilling their duty of care to employees.”
Health and Safety Executive (HSE)
Reducing the instances of occupational lung disease caused by exposure to hazardous substances in the workplace remains a key priority for the HSE. The latest statistics published by the HSE state that 11,000 lung disease deaths a year are estimated to be linked to past exposures at work.
Graeme concludes, “All employers have a duty to protect people from exposure to dust particles - nowhere is this more important than in environments where potentially explosive dust is created.
“Filtermist provides a comprehensive nationwide dust extraction service for facilities of all sizes. From system design and installation, to routine maintenance, LEV testing and air monitoring – our turnkey service ensures workers are safe.”
Contact our dust extraction experts now to discuss your LEV requirements to make sure your people are protected from exposure to airborne dust particles and your business complies with COSHH, DSEAR and IPPC requirements.