Welding is a common industrial process- so common that up to two percent the working population in industrialized counties has been engaged in some sort of welding. The control of exposure to welding fumes is of increasing importance in promoting a healthy safe and productive work environment and technical institutes welding operation is practised in basic work shop lab. Welding fume contains element that in their pure forms can be hazardous to worker health if inhaled or ingested. Respiratory effects observed in welding have including lung function changes. Metal fume fever bronchitis and a possible increases in the incidence of lung cancer. Many questions remain unanswered regarding the casualty and possible underlining mechanism associated with the potential toxic effects of welding fumes inhalation, in our project exhaust fans are used to extract the welding fumes through duct before it could inhaled by the worker to avoid this problem we are implementing a welding fume extractor which acts like a ventilation system. From the system we can control inhalation of the welding fumes, field suggest that 40-50% are more reduction in exposure is possible with portable or fixed WFE system relative to Natural ventilation but that correct positioning of the hood and adequate exhaust flow rates are essential.

1. WELDING FUMES EXTRACTION
Manoj Kumar NP 1
, Chinmaya 2
1, 2
6th
semester, Department of Mechanical Engineering
Coorg Institute of Technology, Ponnampet, South Kodagu
ABSTRACT
Welding is a common industrial
process- so common that up to two percent
the working population in industrialized
counties has been engaged in some sort of
welding. The control of exposure to
welding fumes is of increasing importance
in promoting a healthy safe and productive
work environment and technical institutes
welding operation is practised in basic work
shop lab. Welding fume contains element
that in their pure forms can be hazardous to
worker health if inhaled or ingested.
Respiratory effects observed in welding
have including lung function changes.
Metal fume fever bronchitis and a possible
increases in the incidence of lung cancer.
Many questions remain unanswered
regarding the casualty and possible
underlining mechanism associated with the
potential toxic effects of welding fumes
inhalation, in our project exhaust fans are
used to extract the welding fumes through
duct before it could inhaled by the worker
to avoid this problem we are implementing
a welding fume extractor which acts like a
ventilation system. From the system we can
control inhalation of the welding fumes,
field suggest that 40-50% are more
reduction in exposure is possible with
portable or fixed WFE system relative to
Natural ventilation but that correct
positioning of the hood and adequate
exhaust flow rates are essential.
Keywords: - WFE, MMAW, GMAW,
SAW, FCAW, SCM GTAW, V2O5
I. INTRODUCTION
Despite the advances a welding automation
and control technology, welders are
exposed to the welding fumes and
hazardous gases. The chemical composition
of the particles in these fumes and gases
depend on the welding procedure, the
chemical composition of the shielding gas,
filler metal and the base material, the
presence of coatings, time and severity of
exposure and ventilation.
From the author N T Jenkins, welding
fumes contain elements that in their forms
can be hazardous to worker health if in held
or ingested. Therefore, the chemical
composition of the welding fumes must be
examined when considering fume toxicity.
Various chemical analysis techniques are
presented and their applicability to airborne
particles is described. The fume generation
rates and the concentration of total
chromium and hexavalent chromium, when
stainless steel was welded using flux cored
arc welding with CO2 gas. Concentration of

2. total chromium and hexavalent chromium
were quantified using a method
recommended by American welding
society, inductively coupled plasma atomic
emission spectroscopy and ion
chromatography respectively.
Many of the reported epidemiology
studies are difficult to compare because of
the wide differences in worker’s
populations, industrial settings, welding
techniques, duration of exposure and other
occupational exposures besides welding
fumes. Epidemiological studies have
indicated that large numbers of welders
experience some type of respiratory illness.
Respiratory effects observed include acute
bronchitis, air passage irritation,
pneumoconiosis ‘Arc welder’s siderosis ‘,
occupational asthma and possible increase
in the incidence of lung cancer.
II. OBJECTIVES
 To reduce the emission of toxic gases to the
environment and control the emission rate
of pollution.
 To avoid inhalation of the fumes in a
practise lab.
 To design economical portable fumes
extractor.
 To check the performance of the designed
and fabricated model.
 To check percentage of filtration as per the
standard OSHA and ASHRAE.
Figure 1: Process Flow Chart.
III. DESIGNING AND
FABRICATING THE MODEL
a) Designing procedure: -
 Recognition of the need to develop the
model of welding fumes extraction
system.
 Mechanism: Like motion of the welding
fumes extraction system (portable
types).
 Material selection: The best material
has to be chosen for the model
 Give up the dimension of the machine
elements like length, width, height of
the machine, filter and suction type.
 Generate the detail drawing and send to
a manufacturing unit.
The figure 2 and 3 shows the detailed
drawing to do manufacturing.
Figure 2: Dimensions of welding fume extraction
system.

3. Figure 3: Isometric view of WFE
Fabricated model:-
The figure shows the fabricated
model as per the detailed drawing and now
it is ready for the test, sub assembly parts of
the welding fumes extraction as shown in
table 1 with their specification.
Figure 4: Fabricated welding fume extraction
system.
Table 1: Sub assembly parts list with specification.
Sl.
No
Part
Name
Specification
1 Exhaust
blower
0.5HP, 2800 rpm
2 Sucking
duct
Fibre of 8-meter
length
3 Filter
cloth
40-micron meter,
with spot holes
4 Cartridge
filter
0.5 micron the spot
hole size
IV. EXPERIMENTAL SETUP
The welding process can be carried at
suitable place and specification of the
welding machine with other details as been
shown in table 2.
Table 2: Welding machine specification.
The figure (5) shows the experimental
process in which welding process will be
carried and the sample were collected by
two steps I.e. without filter and with filter.
The samples were collected as per the
standard OSHA and ASHRAE test method.
Sl.
No
Welding parameter Condition
1 Welding type and
method
Arc welding
2 Welding time
(minute)
2Hrs (120
minutes)
3 Nominal voltage
and current
440 v and
250 amps
4 Welding machine Jermex arc
welding
5 Electrode type 3.14 dia, 10
gauge
6 Test plate (base
metal)
Mild steel

4. Figure 5: Testing of the model.
V. RESULT AND DISCUSSION
The principle of design and
fabrication of welding fumes extraction
system has taken role model of vacuum
cleaner.
According to test results when the
system does not have the filter the oxides of
sulphur, oxides of nitrogen and carbon
monoxide are measured as 0.0046, 0.022,
and 4 as rated in the terms of ppm
respectively
Similarly, when the filter has been
attached to a system emitted gases like
oxides of sulphur, oxides of nitrogen are
measured as 0.0038, 0.0213 and 2 as rated
in terms of ppm respectively.
As per the standard of Occupational
Safety and Health Administration (OSHA)
the limiting gas can be given off to the
environment are 5 and 50 ppm for oxides of
nitrogen and carbon monoxide respectively.
Figure 6: Emission rate for different oxides.
From the figure (6) show the emission rate
for (1) Oxides of sulphur and (2) oxides of
nitrogen in the use of with filter and without
filter. As per the standard concerned
obtained value is less than the OSHA
standard.
Figure 7: Emission rate for carbon dioxide.
CONCLUSION
The present work details with
reduction of emission of welding fumes and
create a better heath environment during the
welding process in the technical institute
and industrial application as concerned with
results the emission rate like oxides of
0
0.01
0.02
0.03
without filter
with filter
inppm
Exhaust fumes
oxides of sulphur
oxides of nitrogen
0
500
1000
1500
without filter
with filter
inppm
Exhaust Fumes
carbon momoxide carbon dioxide

5. sulphur, oxides of nitrogen, carbon
monoxide and carbon dioxide has been
reduced when the filter has been installed to
a welding fumes extraction system.
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