LEV Inspection & Test Report

CLIENT:

XXXXXXX LTD

SITE: XXXXXXX

Report Reference: Hinge Room-LEV

System Identification: BeCu ESTA LEV 1 & 2

Survey Conducted By:

Name: Position:

XXXX Environmental Consultant

Signed:

Visit Date: 7th December 2015

Issue Date:

December 2015

Assessment of Level of Control

Satisfactory

System: BeCu ESTA LEV 1 & 2

COSHH Reg. 9

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 7th & 8th December by XXXXX of

XXXXX Ltd without supervision. XXXXX is an Environmental Consultant with XXXXX Ltd.

This report covers the following system: BeCu ESTA LEV 1 & 2, 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 LEV 1 & 2

COSHH Reg. 9

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. No 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 LEV 1 & 2

COSHH Reg. 9

LOCAL EXHAUST VENTILATION PLANT – COSHH REG. 9 EXAMINATION AND TEST

1: Client:

XXXXX

2:

System ID: BeCu ESTA LEV 1 & 2

Location: Hinge Plate Room

Process: Hinge Plate Manufacture (polishing

and drilling)

Initial thorough examination: No

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. No.

Beryllium and copper dust/particulates and fume

Standard PPE Airflow LCA501 Vane anemometer Safety Glasses

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 system

Action Required Priority*

Person to take action

Target Date Date Completed

1 - LEV System Fit appropriate visual indictors to system to enable operator to confirm system is operating satisfactorily

2

2- LEV Logbook Locate system logbook and file in a suitable location. Ensure logbook is includes user manual for system, prevouis test reports etc

2

3-Process Method Statement

Ensure method statement for process includes operators pre-check instructions for LEV system

2

Examiner name

Signature

Client name

Signature

Date December 2015

I accept this report YES /NO

Date

*Priority – e.g. 1 = high, 2 = medium, 3 = routine Examiner: green boxes – Employer: yellow boxes

HOODS/ENCLOSURES System: BeCu ESTA LEV 1 & 2

COSHH Reg. 9

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

Open Area

Sash or Opening

ht.

Face Velocity Capture Distance Hood Static

Pressure

Volumetric Flow Rate Hood ID Actual Mean Measured Required

m2 m m/s m/s m m Pa m

3/h

LEV 1

(Fume

cupboard)

0.178 2.52, 2.76,

2.20, 2.26,

2.18, 2.15

2.35 - - 1505.9

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: No. of Hoods on System: 2 14: Process Conditions at Time of Test:

Max No. to be used at any time: 1 Not in process

15:(a) Hood Static Pressure Gauges 15:(b) Hood Pass/Fail Stickers

Fitted? No 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 LEV 1 & 2

COSHH Reg. 9

17:(a) Type/Description: G/S cylindrical dusting and

plastic flexi-hose

18: Visual Examination Report:

17:(b) Air Temp in Ducts: TP1 – 22.2oC; TP2 – 22.1

oC Ducting in good condition with no

visible damage observed 17:(c) Barometric Pressure:

19: Diameter/

Dimension Duct Area Static

Pressure Velocity

Pressures on

Traverse

Duct Velocity

Test Point ID

Actual Measured

Mean Transport Velocity

Duct Volume

Flow (mm) (m

2) (Pa) (Pa) (m/s) (m/s) (m

3/h)

LEV 1

(T.P-01)

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 m3/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

N/A

22: Fan Motor Data: 23: Filter/Air Cleaning Devices:

Make/Model ESTA SRF K-10 FM Make/Model ESTA SRF K-10 FM

Type Centrifugal Type

Volume Flow 950 (m3/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 No

Transmission Electrical Monitoring Gauges etc. - Operational Check

No

Rotation Direction Correct – anti-

clockwise

Recirculation of Filtered Air?

Yes

System: BeCu ESTA LEV 1 & 2

COSHH Reg. 9

24: Return of Exhaust Air to Workroom

Filter Efficiency Not assessed Measurement Technique

Static Pressure at Inlet, Pa Not assessed

Estimate of concentration of contaminant in returned air

Not assessed

Comments None

Recommendations and priority* None

* e.g. 1 = high, 2 = medium, 3 = routine

25: Make-up air

Adequate quantity Yes Measurement Technique

Induced draughts No

Comments None

Recommendations None

26: Alarms

Hood / enclosure No

Duct No

Air cleaner No

Air mover No

Returned air No

Comments None

Recommendations None

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

System: BeCu ESTA LEV 1 & 2

COSHH Reg. 9

28 Schematic Drawing of System:

BeCu ESTA LEV 1 & 2

ESTA FAN/

FILTER UNIT LEV 1

TP01

TP02

400m

m

445mm

LEV 2

G/S DUCT 140mm DIA

PLASTIC FLEXIHOSE

65mm DIA

G/S DUCT

60mm DIA

BENCH

MINI

PILLAR

DRILL

BENCHFACE 60mm DIA

Damper

Damper

System: BeCu ESTA LEV 1 & 2

COSHH Reg. 9

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 LEV 1 & 2

COSHH Reg. 9

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.

No 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 pre-checks 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 substances in Hinge Room

Yes Low risk. Client requested to ensure processes, where practicable, are not taking place during LEV examination and test Disposable overalls/PPE should be worn to protect normal clothing, where necessary. XXX Engineers fully trained in COSHH awareness procedures.

Follow procedures given in method statement and COSHH awareness guidelines.

Electrical hazards Yes Low Risk. Access not required to areas of equipment/machinery containing live electrics All testing equipment uses low voltage batteries.

None

Access and egress to working area

Yes Low Risk: XXX Engineers made aware of client policy on access and egress during site induction.

If engineer deems access unsafe the task shall be halted and the Engineering Manager informed

Chemical hazards Yes Low Risk: No 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.

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.

Noise Yes Low Risk: Process does not create significant noise level Noise created by survey activities is unlikely to be significant. Ear protection available if required to control noise exposure from plant activities. Noise meters and trained operators are available to carry out monitoring if required. XXX Engineers receive noise awareness training

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.

Manual handling Yes Low Risk: Survey tools and equipment are lightweight. Stepladders and ladders are suitable for carrying by one person unaided. Manual handling awareness training provided to XXX Engineers

Moving of plant or manufactured items to be undertaken by XXXXX Ltd employees

Mechanical

No Low Risk: No machinery to be operated, with the exception of the LEV, during the examination and test. LEV to be isolated during examination of filters. Test of fan direction to be undertaken by site engineer

None.

Fire Yes Low Risk: Follow site fire safety rules.

Check location of fire exits and escape routes before commencing work.

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.

Be aware of the risk of sharp edges, etc being present in survey area

Slips, Trips and Falls Yes Low Risk: XXXXX Ltd policy for all production areas to be kept clean and tidy

Engineering Manager to be informed if poor housekeeping observed

Assessment prepared by:

Name XXX Date: 07/12/15

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