Large-Scale Weld Fume Extraction System for an Engineering Workshop
Project overview
A‑Mac Environmental was commissioned to provide a new local exhaust ventilation (LEV) solution for a busy welding area within a large engineering workshop.
The system needed to capture and remove welding fumes from two substantial work areas while allowing employees to work safely around large components and equipment.
A‑Mac Environmental was commissioned to provide a new local exhaust ventilation (LEV) solution for a busy welding area within a large engineering workshop.
The system needed to capture and remove welding fumes from two substantial work areas while allowing employees to work safely around large components and equipment.
The Challenge
Welding processes produce hazardous airborne contaminants, including fine metal particles and gases. Without effective extraction, these contaminants can spread throughout the workshop, exposing welders and other employees.
Due to the size of the components being handled, conventional extraction arms were not suitable for this application. The customer needed a larger extraction solution that would cover both welding areas, contain the fumes and prevent them from spreading into the surrounding workshop.
The system also needed to maintain the correct airflow through the ductwork, filter contaminated air, and provide clear performance monitoring.
The A‑Mac solution
The new LEV system incorporates two large Plymovent canopy extraction hoods, each measuring approximately 3.5 metres by 5.5 metres.
The hoods were positioned directly above the welding areas to capture the rising welding-fume plume. Curtains were installed around the canopies to improve containment, limit the effects of workshop draughts and encourage smoother airflow into the extraction system.
Both canopy hoods were connected to 500 mm diameter galvanised ductwork leading to a Plymovent MDB‑20 cartridge filtration unit. The filter uses an automatic reverse-jet cleaning system to help maintain performance and extend filter life.
Airflow is provided by a Plymovent SIF 20000/LI centrifugal fan with a 22 kW direct-drive motor. A Plymovent ControlPro system monitors the installation and provides differential-pressure readings and system alarms.
Commissioning and LEV testing
Once the installation was complete, A‑Mac Environmental carried out a thorough examination and commissioning test in accordance with the Control of Substances Hazardous to Health Regulations 2002 and relevant HSE guidance.
Measurements were taken throughout the ductwork to confirm that the system was providing the required performance. The left extraction branch achieved a duct velocity of 10.32 m/s, while the right branch achieved 11.02 m/s. The main fan inlet recorded 20.96 m/s, with a total system airflow of approximately 14,876 m³/hr.
Both extraction branches achieved the minimum transport-velocity benchmark of 10 m/s used for this welding-fume application.
The canopy hoods, ductwork, filtration unit, fan and monitoring controls were inspected and found to be in good condition.
The Result
The new extraction system passed its commissioning examination and was assessed as providing adequate control of the fumes produced by the welding process.
The combination of large canopy hoods, containment curtains and high-capacity filtration now helps capture welding fumes before they can spread through the workshop. Automatic filter cleaning and performance monitoring also help the customer maintain reliable extraction and identify potential system issues.
The completed installation provides the customer with a cleaner working environment and an effective engineering control measure for welding fumes under COSHH.
Every welding-fume extraction system must be correctly designed, commissioned, tested and maintained to ensure it continues to protect employees.
A‑Mac Environmental provides complete industrial ventilation and LEV services, including system design, installation, commissioning, COSHH thorough examination and testing, maintenance and repairs.
If welding fumes or airborne contaminants are affecting your workplace, contact A‑Mac Environmental to arrange a site survey and discuss the most suitable extraction solution.