Professional Documents
Culture Documents
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Code of Practice
Published by the Occupational Safety and Health Service Department of Labour New Zealand
TABLE OF CONTENTS
1 GENERAL 1.1 Introduction 4 1.2 Legislative Requirements 5 1.3 Spray Booths and Collection Units 5 1.4 Fire and Explosion Hazards 5 1.5 Toxicity Hazard 6 1.6 Electrostatic Powder Coating Guns 6 2 PLANT DESIGN AND OPERATION 2.1 Principles of Hazard Reduction in Plant Design 7 2.2 Design of Spray Booth 8 2.3 Design and Operation of Powder Extraction and Collection Systems 8 2.4 Explosion Prevention Using Single-Factor Method 8 2.5 Explosion Prevention Using Double-Factor Method 9 2.6 Protection of Plant from Effect of Dust Explosions 10 2.7 Ovens 11 2.8 Protection of Operators Health 11 2.9 Cleaning 11 2 10 General 11 3 ELECTRICAL EQUIPMENT 3.1 General 12 3.2 Electrical Equipment in the Hazardous Area 12 3.3 Earthing in the Hazardous Area 13 3.4 Electrostatic Powder Coating Guns 13 APPENDIX A APPENDIX B APPENDIX C Examples of Powder Concentration and Lower Explosive Limit Calculations Explosive Characteristics of Plastic Powders (Representative Values) Examples of Possible Arrangements for Powder Collection Units 4
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APPENDIX D
1. GENERAL E
1.1 Introduction
1.1.1 The purpose of this Code is to indicate the potential hazards in electrostatic powder coating and to specify the means by which these hazards may be minimised. The Code is divided into three parts: (1) A general section; (2) A section which gives mainly special details for compliance with the Factories Act 1946 and the Spray Coating Regulations 1962; and (3) A section which gives mainly special details for compliance with the Electrical Wiring Regulations 1976. 1.1.3 Electrostatic powder coating is a process whereby particles are charged electrostatically to a high voltage and then deposited upon the surface of an earthed object. Coating with powder by the electrostatic spraying technique is similar in principle to electrostatic spray coating with paint. The primary difference is the absence of solvent; paint is sprayed as a suspension in a solvent base, whereas powders are applied as fine particles in a dry condition. 1.1.4 The absence of solvent in dry powder applications removes the problems of paint overspray, solvent fumes and odours, and the risk of fire from flammable liquids. However, it does not eliminate hazards. Fine plastic powders in suspension in air can give rise to dust explosions, and can be injurious to health if inhaled in sufficient quantities. Precautions must be taken to reduce these hazards to an acceptable level. If adequate precautions are adopted at the outset, costly modifications to equipment will be avoided later. Powder should only be sprayed in a booth, as for spray painting, but unlike wet paint overspray, the oversprayed powder can be recovered and re-used. For powder spraying the booth is backed up by powder collection units, to which the powder is conveyed in the ventilating air stream via connecting ducting. Not all plastic powders are combustible or provide the same hazards from fire and explosion. The majority of powders used at present in New Zealand are epoxy resins and these powders have the greatest explosion hazard. Polyester powders have a similar explosion hazard rating and other powders such as acrylic and polythene have lower explosibilities. Although a dust cloud of polyvinyl chloride (PVC) powder is not explosive, PVC may give rise to toxic fumes during curing in ovens. Polyurethane powders may also give rise to irritant fumes during curing, hence ovens using these powders must be ventilated. As with paint, electrical equipment which sparks or has a hot surface could be a hazard, but it requires a higher energy spark and a higher temperature than that for a flammable vapour in order to ignite a dust cloud. The electrical
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1.1.2
1.1.5
1.1.6
1.1.7
1.1.8
E V I Requirements 1.2 Legislative H C 1.2.1 For electrostatic powder coating compliance with this Code will be accepted R A by the Department of Labour as satisfactory in meeting the requirements of
Section 48A of the FactoriesAct 1946, which requires all practicable steps to be taken to eliminate the hazards from explosible dusts. 1.2.2 Regulation 37 of the Spray Coating Regulations 1962 requires spray coating by electrostatic means to be authorised in writing by the Chief Inspector of Factories. Compliance with this Code provides the conditions under which the Chief Inspector will issue authorisation. Any alteration such as the use of a different electrostatic powder coating gun requires a new approval. Compliance with this Code will be accepted as meeting Regulations 67 and 94 of the Electrical Wiring Regulations 1976. Emissions from the powder collector to the outside air must comply with the Clean Air Act 1972. An efficient cyclone would normally be sufficient to meet this requirement.
equipment also requiries a different construction than that for flammable vapours in order to protect against the risk of a dust explosion or fire.
1.2.3 1.2.4
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1.4.3 1.4.4
The concentration of powder in air must be above a minimum value termed the lower explosive limit (LEL) in order for an explosion to occur. The LEL value changes with the type of powder in use (see Appendix B), but will be in the range 20 - 60 g/m3 for explosible powders. There is also a maximum concentration of powder in air above which explosions will not occur. This figure is of the order of several kilograms per cubic metre, but is very ill-defined and in practice could not be stated with any degree of accuracy. It is safer, therefore, to assume that the powder can explode at all concentrations above the minimum value. A cloud of powder in air, which is of sufficient concentration, will explode only if an ignition source is present. The source of ignition must be of the required energy for it to ignite a dust cloud. This is referred to as the minimum ignition energyand is normally expressed in joules or millijoules. Most values fall in the 10 to 40 millijoules range (seeAppendix B). The source of ignition must be at a certain minimum temperature to ignite a dust cloud. This is referred to as the ignition temperature. Typical values for a dust cloud range from 4000C to 5500C (see Appendix B). It should be noted that a layer of dust will ignite at considerably lower temperatures than a dust cloud; the thicker the layer of dust the lower the ignition temperature. There are a number of possible sources of ignition such as electrical equipment, cigarettes and matches, unearthed conductors producing static electricity, naked flames and hot surfaces. The whole workroom containing the powder spraying and collection equipment can be at great risk if accumulations of powder are allowed to arise in this area.
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1.4.8
1.4.9
1.5.2 1.5.3
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objects, are the most likely to accumulate charge, although poor conductors, such as plastics, can also accumulate a charge but not to a level which is dangerous for combustible dusts. Because there is no New Zealand authority for testing electrostatic spray guns, reliance must be placed on overseas specifications.
2.1.4
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2.1.7
Inhalation of powder is avoided by providing sufficient air movement in the breathing zone of operators. When this is not practical suitable protective equipment must be provided and worn.
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The average concentration of the coating powder in the booth is determined from the maximum rate of powder that can be discharged from the guns in relation to the volume of air extracted by the ventilation system at its lowest capacity under operating conditions. SeeAppendixA for sample calculation. A plate must be affixed to the booth showing the minimum air volume rate (see AppendixA) and the design (actual) air volume rate. This plate shall conform to the pattern shown in Figure 1 and be situated in a conspicuous position. Markings on the plate shall be legible and permanent. If a new or additional gun is used giving a different maximum powder flow rate, then the plate must be altered to give the new minimum air flow rate (see also Section 1.2.2.). Some means must be provided so that, in the event of the air rate falling below the minimum, the powder supply to the spray gun will be cut off. An air flow switch or a switch operating on a pressure differential can be used for this purpose. If an air flow switch is installed, it must be on the clean side. Although the concentration may be above the explosive limit close to the gun, any explosion in this region would not be sustained outside and only a minor puff would result from a source of ignition existing very close to the gun.
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2.5.10
All fans in the collection system shall be situated on the clean side of the collection units, and shall be of a type where the motor is fitted external to the ducting. Downstream from the primary dust collector is considered to be on the clean side.
If explosion suppression is used as the means to protect the plant, then it must be designed and supplied by a firm with recognised expertise in this area. If the plant is designed to withstand a pressure of 700 kPa, then no other means of protection is necessary. Details of the plant design must be provided when seeking approval.A flame arrestor or fast-acting valve must be installed in the ducting close to the booth in order to prevent the flame front from any explosion returning to the booth. The fast-acting valve should be activated by a pressure or temperature detector located in the powder collector (or for a suppression system). If the plant is explosion vented, then either the plant should be located outside the building or the relief vent must be ducted to outside the building. The explosion vents must discharge at least 3 m above the ground or be located in an unfrequented place. The explosion venting standard accepted by the Department of Labour is National Fire Protection Association (N.F.P.A.) Code No. 68, Explosion Venting Guide 1978. If the plant is required to withstand pressure above 20 kPa, then details must be provided, when seeking approval, to confirm that the plant can withstand the design pressure. Suppliers of the collection system will also need to specify the explosion venting area, the volume of the collecting vessel, the pressure at which the vents release, and the length of the explosion relief ducting.
2.6.3
2.6.4
2.6.5
If the length of the explosion relief vent ducting is longer than 2 m, or if it contains any bends greater than 10, then either the vessel and ducting must be capable of withstanding a higher pressure than 20 kPa or the cross-section of the explosion relief vent must be increased.A distance of 6 m is the maximum allowable length for an explosion relief vent duct when either the cross-section of the duct must be twice the area of the vent or the vessel must be capable of withstanding twice the pressure required for that vent area based on N.F.P.A. Code No. 68. The requirement for distances between 2 m and 6 m is found by proportion, e.g. for 4 m the area or pressure must be increased by 50%. If the dust collector has an unobstructed channel between where the powder is collected and the rest of the collector, then the whole powder collector must be explosion vented.A flame arrestor or fast-acting valve must also be installed close to the booth. If a cyclone uses a rotary valve or an automatically operated double-flap valve to separate the collecting vessel from the rest of the collector, then only the collecting vessel needs to be explosion vented or built to withstand 700 kPa. This criteria also applies to a filter bag unit when it is used in addition to a cyclone.
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2.7 Ovens
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2.7.1 2.7.3
Powder shall not be allowed to escape into an oven from any source. The temperature in the oven shall be kept below that at which the plastic will degrade and produce fumes of the products of decomposition (i.e. normally 2400C). To achieve this a temperature controlling device shall be fitted to control the temperature in the oven. The temperature controller must incorporate a fail-safe device, e.g. a fusible link. Ovens used to cure PVC or polyurethane powder must be vented to outside the factory. At least 10 m of air per kg of polyurethane powder must be provided in continuous ovens. Ovens used to cure other powders may not need to be vented outside the factory depending on the size and operation of the curing process.
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2.8.3
2.9 Cleaning
2.9.1 The spray booth, ducting, powder collection units and the surrounding workroom area shall be effectively cleaned at regular intervals to prevent accumulations of powder. Cleaning shall preferably be carried out with an industrial vacuum cleaner, of a type powered by compressed air or dust-excluding ignition-proof type of electrical equipment. If the vacuum cleaning is not of this type, then it cannot go into the hazardous area while spraying is in operation.A centralised vacuum cleaning system utilising a cyclone or bag filter unit is also acceptable provided it has adequate protection against dust explosions. Cleaning shall not be carried out by brushing, although sweeping deposits from the inside of the booth directly into the collection system is permissible provided the extraction system is kept in operation. Powder which is not to be recovered for re-use shall be wetted before disposal.
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2.9.4
2.10 General
2.10.1 Operators of electrostatic powder spraying equipment shall be adequately trained in the use of the equipment and this training shall be the responsibility of the occupier. 11
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2.10.2
Operators shall be made aware of the provisions of the Code where they relate to the operator or to the operation of the booth. Such provisions shall be made known to the operator by the occupier, before the equipment is used. No flammable paints or solvents shall be used or kept within 2 metres of the booth in a container made of conductive material unless they are earthed in accordance with Section 3.3.2. It is recommended that the inside surface of the booth, ducting and cyclone be painted or coated with a nonconductor as then powder will be less likely to stay on these surfaces. This will both reduce the explosion hazard and increase the ease with which colour changes can be carried out. Two cyclones in parallel may be used to make possible more rapid changes in colour. Plate to be affixed to spray booth indicating its air extraction capacity DESIGNAIR VOLUME RATE m3/s
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2.10.4
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3. ELECTRICAL EQUIPMENT
3.1 General
3.1.1 All electrical equipment must comply with the Electrical Wiring Regulations 1976. An extract from the Australian SAA Wiring Rules published by SANZ, MP 6105: 1976 Electrical Wiring in Hazardous Locations, is also to be used for guidance as it is intended to include most of this material in the Electrical Wiring Regulations. When the average powder concentration in the spray booth be above 25% of the LEL, then the concentration is sufficient to require designation of a hazardous area. The area inside the spray booth and within 2 m of any openings in the spray booth will be inside the hazardous area. If because of poor housekeeping or other reasons there are considerable quantities of explosive dust in the work area, this area shall also be designated a hazardous area.
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3.2.3
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Light fittings used to illuminate the interior of the booth and any other light fittings within the hazardous area must comply with Section 3.2.1. Alternatively, the fittings can be mounted outside the booth and separated from the interior by dust-tight panels or wired or reinforced glass. Plugs and plug sockets used in the hazardous area shall be provided with an interlocking switch so arranged that the plug cannot be inserted or withdrawn with the switch in the on position and that the switch cannot be in the on position unless the plug is in the socket. The plug and plug socket shall be so constructed and installed that powder will not accumulate in the socket.
3.3.2
3.3.3
3.3.4
3.3.5 3.3.6
3.4.2
3.4.3
APPENDIX A
Examples of Powder Concentration and Lower Explosive Limit Calculations
Suppose a booth is equipped with two spray guns both capable of a maximum discharge rate of 5 g/s, then the total maximum discharge rate = 5 + 5 = 10 g/s. If the air flow rate is 0.8 m3/s then the average powder concentration = 10 (g/s,) 0.8 (m3 /s) Suppose the powder being sprayed is epoxy, then the minimum air volume rate for 50% of LEL 10 (g/s) = 0.5 x 53 (g/m3) (see Appendix B) and the minimum air volume rate for 25% of LEL 10 (g/s) = 0.25 x 53 (g/m3) (see Appendix B) = 0.76 m3/s = 0.38 m3/s = 12.5 g/m3
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3.4.4
motor driven devices, shall be excluded from the interior of booths, except in the case of approved spray-guns where the high-voltage generator is sealed into the gun. The high tension cables leading to guns shall be protected against damage during operation.
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APPENDIX B
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Not ignitable Not ignitable Not ignitable 410 520 500 420 500 552 517 655 524 620 50 20-66 0-10
Not ignitable 1 or 2 1 1 1 1 or 2
(1) Results on a scale 0-100. 100 indicates severest hazard, 0 - no ignition under test conditions
APPENDIX C
Examples of Possible Arrangements for Powder Collection Units
Example A. In this example the booth uses the single-factor method while the cyclone has both the single-factor method and protection against the effect of an explosion (see Fig. 2). Example B. In this example the booth uses the double-factor method while the cyclone has protection against the effect of an explosion (see Fig. 3). Example C. This type of cabinet is portable and has protection against the effect of an explosion (see Fig. 4).
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KEY 1. Average concentration below 25% of LEL (see 2.4.1) 2. Pressure-differential switch installed (see 2.4.5) 3. Rotary valve installed (see 2.6.7) 4. Vessel built to withstand 700 kPa (see 2.6.2 and 2.6.7) 5. Air exhausted outside factory (see 2.3.3) 6. No earthing of object required as special type of gun used (see 3.3.4)
Fig. 2 Example A
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KEY 1. Hazardous area a set distance from booth opening (see 2.5.5) 2. Average concentration below 50% of LEL (see 2.5.1) 3. Object in booth earthed (see 3.3.2) 4. Booth constructed of nonconductive material (see 2.5.4) 5. A flame arrestor or fast-acting valve installed (see 2.6.6) 6. Powder gun interlocked with fan (see 2.5.3) 7. Explosion vent installed (see 2.6.3) 8. Air exhausted outside factory (see 2.3.3)
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Fig. 3 Example B
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KEY 1. Average concentration below 50% of LEL 2. Electrodes installed - source of ignition permissible as below LEL 3. Concentration above LEL 4. Explosion vent installed (see 2.6.3) - not vented outside but has flame arrestor (special case for portable unit) 5. Object in booth earthed (see 3.3.2) 6. Cabinet constructed of conductive material and therefore earthed (see 2.5.4)
Fig. 4 Example C
APPENDIX D
At the time that this code was printed the following information was available: Sames Company manufactures a gun which uses a technique which overcomes poor earthing; and Gema manufactures an earthing control unit (Nz agents - Gunn-Gollin Limited).
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