1、Guide forEstimatingWeldingEmissions for EPAandVentilationPermit ReportingAWS F1.6:2003An American National Standard550 N.W. LeJeune Road, Miami, Florida 33126AWS F1.6:2003An American National StandardApproved byAmerican National Standards InstituteFebruary 25, 2003Guide for EstimatingWelding Emissio
2、ns for EPAand Ventilation Permit ReportingPrepared byAWS Project Committee on Fumes and GasesUnder the Direction ofAWS Committee on Safety and HealthApproved byAWS Board of DirectorsAbstractThis document assists companies in estimating emissions from welding processes for EPA reporting purposes by c
3、hoos-ing the simplest applicable method and following its steps. Example calculations are included.Key WordsEmission factors, welding fumes, environmental reportingStatement on Use of AWS American National StandardsAll standards (codes, specifications, recommended practices, methods, classifications
4、, and guides) of the AmericanWelding Society (AWS) are voluntary consensus standards that have been developed in accordance with the rules of theAmerican National Standards Institute (ANSI). When AWS standards are either incorporated in, or made part of, docu-ments that are included in federal or st
5、ate laws and regulations, or the regulations of other governmental bodies, theirprovisions carry the full legal authority of the statute. In such cases, any changes in those AWS standards must be ap-proved by the governmental body having statutory jurisdiction before they can become a part of those
6、laws and regula-tions. In all cases, these standards carry the full legal authority of the contract or other document that invokes the AWSstandards. Where this contractual relationship exists, changes in or deviations from requirements of an AWS standardmust be by agreement between the contracting p
7、arties.International Standard Book Number: 0-87171-712-3American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126 2003 by American Welding Society. All rights reservedPrinted in the United States of AmericaAWS American National Standards are developed through a consensus standards development
8、 process that bringstogether volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the processand establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, orverify the accuracy of any information or
9、 the soundness of any judgments contained in its standards.AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether spe-cial, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or relianc
10、e on thisstandard. AWS also makes no guaranty or warranty as to the accuracy or completeness of any information published herein.In issuing and making this standard available, AWS is not undertaking to render professional or other services for or onbehalf of any person or entity. Nor is AWS undertak
11、ing to perform any duty owed by any person or entity to someoneelse. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek the adviceof a competent professional in determining the exercise of reasonable care in any given circumstances.This standard
12、may be superseded by the issuance of new editions. Users should ensure that they have the latest edition.Publication of this standard does not authorize infringement of any patent. AWS disclaims liability for the infringementof any patent resulting from the use or reliance on this standard.Finally,
13、AWS does not monitor, police, or enforce compliance with this standard, nor does it have the power to do so.On occasion, text, tables, or figures are printed incorrectly, constituting errata. Such errata, when discovered, are postedon the AWS web page (www.aws.org).Official interpretations of any of
14、 the technical requirements of this standard may be obtained by sending a request, in writing,to the Managing Director, Technical Services Division, American Welding Society, 550 N.W. LeJeune Road, Miami, FL33126 (see Annex B). With regard to technical inquiries made concerning AWS standards, oral o
15、pinions on AWS standardsmay be rendered. However, such opinions represent only the personal opinions of the particular individuals giving them.These individuals do not speak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or inter-pretations of AWS. In additio
16、n, oral opinions are informal and should not be used as a substitute for an official interpretation.This standard is subject to revision at any time by the AWS Safety and Health Committee. It must be reviewed every fiveyears, and if not revised, it must be either reapproved or withdrawn. Comments (r
17、ecommendations, additions, ordeletions) and any pertinent data that may be of use in improving this standard are required and should be addressed toAWS Headquarters. Such comments will receive careful consideration by the AWS Safety and Health Committee andthe author of the comments will be informed
18、 of the Committees response to the comments. Guests are invited to attendall meetings of the AWS Safety and Health Committee to express their comments verbally. Procedures for appeal ofan adverse decision concerning all such comments are provided in the Rules of Operation of the Technical Activities
19、Committee. A copy of these Rules can be obtained from the American Welding Society, 550 N.W. LeJeune Road,Miami, FL 33126.Photocopy RightsAuthorization to photocopy items for internal, personal, or educational classroom use only, or the internal, personal, oreducational classroom use only of specifi
20、c clients, is granted by the American Welding Society (AWS) provided that theappropriate fee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, Tel: 978-750-8400;online: http:/.iiiPersonnelAWS Safety and Health CommitteeS. R. Fiore, Chair Edison Welding InstituteR. J.
21、Tucker, 1st Vice Chair Dalloz SafetyS. P. Hedrick, Secretary American Welding SocietyJ. M. Antonini NIOSHK. Bancroft ConsultantK. L. Brown The Lincoln Electric CompanyD. E. Clark Idaho National Engineering LaboratoryC. W. Duffield U.S. Geological SurveyJ. D. Jennings Miller Electric Manufacturing Co
22、mpanyS. F. Kane Brookhaven National LaboratoryK. A. Lyttle Praxair, IncorporatedA. F. Manz A. F. Manz Associates*O. J. Fisher Consultant*J. F. Hinrichs Friction Stir Link, Incorporated*M. T. Neu Caterpillar, Incorporated*R. J. Simonton Sandia National Laboratories*D. H. Sliney U.S. Army Center*R. M.
23、 Tuggle U.S. Department of Energy*M. E. Wallace U.S. Public Health ServiceAWS Subcommittee on Fumes and GasesD. E. Clark, Chair Idaho National Engineering LaboratoryS. R. Fiore, Vice Chair Edison Welding InstituteS. P. Hedrick, Secretary American Welding SocietyK. L. Brown The Lincoln Electric Compa
24、nyJ. W. Dimler JWD AssociatesK. A. Lyttle Praxair, IncorporatedJ. J. Palach Hobart Brothers of CanadaR. B. Smith Select-ArcA. M. Zhivov Zhivov for moreinformation, see ANSI Z49.1, Safety in Welding, Cutting,and Allied Processes. This standard makes use of theU.S. Customary Units. Approximate mathema
25、ticalequivalents in the International System of Units (SI) areprovided for comparison in parentheses ( ) or in appro-priate columns in tables or figures.2. Referenced Documents2.1 The following ANSI standard1is referenced in themandatory section of this standard:ANSI Z49.1, Safety in Welding, Cuttin
26、g, and AlliedProcesses.2.2 The following EPA document2is referenced in themandatory section of this standard:The Plain English Guide to the Clean Air Act, EPA-400-K-93-001, April 1993.1. This ANSI publication may be obtained from Global Engi-neering Documents, 15 Inverness Way East, Englewood, CO801
27、12.2. This EPA publication may be obtained from the U.S. Environ-mental Protection Agency National Service Center for Environ-mental Publications, P.O. Box 42419, Cincinnati, OH 45242, ormay be viewed at the EPA Web site (http:/www.epa.gov).3. Estimating Emissions3.1 Considerations in Estimating Emi
28、ssions. Weldingfume particulates are essentially submicron in size andare considered to be in the PM-10 classification (parti-cles less than or equal to 10 m aerodynamic diametersize range, as defined in The Plain English Guide to theClean Air Act, EPA-400-K-93-001, April 1993). Fre-quently, calcula
29、ted total emissions from welding opera-tions are below reporting threshold values and thereforeestimating the amount of components of this total maynot be required. Because of this, process-based estimatescan be used for most reporting without significant impacton operations. Thus, useful estimates
30、can be obtainedwithout extensive research, calculations or testing.The calculation for the process-based estimate is sim-ple and straightforward. If a more precise estimate is de-sired, the other methods discussed in 3.3 offeralternatives. As each method increases in precision, so dothe complexity,
31、time and cost for estimation increase. Itis best to start with the easiest method first and see if itmeets the stated need.Emissions from sources other than the welding con-sumable (such as zinc oxide fume from welding galva-nized material) are not included in estimates fromMethods 1, 2, or 3. Estim
32、ates for emissions from weldingwhere individual constituents are required to be reportedshould start with Method 2 under 3.3.3.1.1 Reporting Requirements for the Componentsof the Welding Fume. Estimating the amounts of thecomponents of welding fume may not be necessary forreporting, even though the
33、fume may contain materialslisted as “Hazardous Air Pollutants” by the EPA (see2.2). Refer to local regulations to determine the applica-ble threshold levels for total emissions or emissions ofcomponent materials. Though local regulations vary, ifthe calculated total emissions from the facility (weld
34、ingand non-welding related) are less than the reportingthreshold values, estimating the amount of the compo-nents of this total may not be required.Guide for Estimating Welding Emissionsfor EPA and Ventilation Permit ReportingAWS F1.6:20032Examine the Material Safety Data Sheet (MSDS) forthe welding
35、 consumable to determine the components ofthe fume. If individual component reporting thresholdsare higher than the total emissions estimated, then furthercalculations may not be required.If reporting is required for the components, estimatethe emissions factor by electrode specific method out-lined
36、 in 3.3.2. Generally, only certain elements are re-quired to be reported. Reportable elements found insome common welding processes include manganese,chromium, nickel, and copper.3.2 Emissions Calculations. Each method starts with theequation below. Assuming that all of the welding fume isexhausted
37、from the building by ventilation, the totalemissions (in pounds or kilograms of welding fume) canbe determined by multiplying the total amount of weld-ing consumables used by the emission factor. The emis-sion factor is determined using one of four methodsdiscussed in 3.3. The total amount of consum
38、ables can beestimated based upon purchases over the reportingperiod.E=Mc EFwhereE = emissions (in pounds or kilograms)Mc = amount of consumables used over the report-ing time period (in pounds or kilograms)EF = emission factor from one of the estimationmethods (measured in % of consumables con-verte
39、d to fume)If your reporting requirements allow you to considerthe use of a dust collector, the amount of fumes emittedafter filtration can be calculated as follows:Efiltered=E (1 FE)whereE = emissions (in pounds or kilograms)Efiltered= emissions after filtering by the dust collec-torFE = filter effi
40、ciency of the dust collector3.3 Methods for Estimating Emission Factors(1) Method 1: Process-based estimates (where emis-sions are expected to be low).(2) Method 2: Electrode specific estimates (wheremore precision than Method 1 is desired).(3) Method 3: Procedure specific estimates (wheremore preci
41、sion than Method 2 is desired).(4) Method 4: On-site testing (where more precisionthan Method 3 is desired).3.3.1 Method 1: Process-Based Emission FactorEstimates. The factors in Table 1 come from a review oftypical fume generation data for various consumables ineach category. Based upon knowledge o
42、f the weldingindustry and emission factors for typical electrodes fromthese classes, the emission factors shown in Table 1represent conservative estimates for the class (i.e., manyelectrode specific factors are lower than this process-based factor).The following is a process-based method example cal
43、-culation: A manufacturer used 4500 lbs (2040 kg) ofER70S-6 solid wire electrode last year.E=Mc EFMc = 4500 lbs (2040 kg)EF = 0.8% (for solid wire, taken from Table 1)E = 4500 lbs (2040 kg) 0.008= 36 lbs (19 kg)Total emissions for last year are estimated to be 36 lbs(19 kg), primarily iron oxide and
44、 some manganese com-pounds (based on data from the electrode MSDS).If a more accurate estimate is desired, or if further in-formation is required regarding specific compounds inthe fume, use the electrode specific method described in3.3.2.3.3.2 Method 2: Electrode Specific Emission Fac-tor Estimates
45、. Based upon the AWS classification ofthe electrode used, the emission factor can be foundin Annex A. Annex A also includes emission factorsof Hazardous Air Pollutants (HAP) specific to certainelectrodes.Elemental emissions are calculated by multiplying thetotal fume emission by the elemental fume c
46、hemistrypercentage found in Annex A. The following are elec-trode specific method and elemental emissions examplecalculations:A manufacturer used 4500 lbs (2040 kg) of ER70S-6solid wire electrode last year.E=Mc EFMc = 4500 lbs (2040 kg)EF = 0.7% (for ER70S-6, taken from Annex A)E = 4500 lbs (2040 kg
47、) 0.007= 31.5 lbs (14.3 kg)Table 1Process-Based Emission Factors Estimates(Ferrous-Based Consumables Only)Welding Consumable EF (%)Solid wire, gas shieldedCored wire, gas shielded (except EXXT-5)Cored wire, non-gas shielded, and EXXT-5Manual electrode0.81.33.52.8AWS F1.6:20033Total emissions for las
48、t year is estimated to be31.5 lbs (14.3 kg), primarily iron oxide and some manga-nese compounds (based on data from the electrodeMSDS).Elemental emissions are calculated by multiplying thetotal fume emissions by the elemental fume chemistrypercentage found in Annex A.This manufacturer is required to
49、 report the emissionsof manganese, chromium, nickel, and copper. Annex Aindicates that the elemental content of the fume fromER70S-6 is 8.8% manganese and 0.6% copper (the chro-mium and nickel content is shown as negligible in AnnexA). Therefore:Manganese emissions= 31.5 lbs (14.3 kg) of total fume 0.088= 2.8 lbs (1.3 kg) of manganeseCopper emissions= 31.5 lbs (14.3 kg) of total fume 0.006= 0.2 lbs (0.09 kg) of copperIf a more precise estimate is desired, or if further in-formation is required regarding specific compounds inthe fume, use the procedure s
