Shipyard Stormwater Best Management Practice #5: Metal Arc Welding (MAW)

BMP Goal(s)
Significant reduction or elimination of pollutant emissions per unit length welded.

References
Shipyard Core Processes Pollutant of Concern Matrix document Welding Pollution Pathway Analysis document Welding Process Guidance Elements section on page two

Background
This BMP addresses the discharge of pollutants of concern from the process of Metal Arc Welding. The significant and potentially significant pollutants of concern addressed by this BMP have been identified in the Shipyard Core Processes & Pollutants of Concern Matrix as: copper, zinc, nickel, lead, iron, chrome and aluminum. This section explains the rational for developing and implementing the BMP. It identifies the pollutant(s) being controlled, the potential sources of the pollutant(s), and the physical pathway the pollutant(s) follows to reach the facilitys stormwater flow. If practicable, this section also includes an estimate of the potential pollutant loading reduction, based upon the Pollution Pathway Analysis or other referenced studies.

Best Management Practice Description

Develop and implement a comprehensive job specific process management plan for Metal Arc Welding, designed to achieve the goal of this BMP.

Monitoring and Reporting

The implementation of this BMP will be monitored to determine effectiveness in achieving the goal. Monitoring will be done on a job-by-job basis, with specific metrics used as appropriate for the job. Examples of metrics that may be used for this process include: Rod/wire consumption/unit length welded Fume/particulate matter emissions/unit length welded Training records Control factors for add on control equipment Process operation variables necessary to optimize efficiency/effectiveness

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Shipyard Stormwater Best Management Practice #5: Metal Arc Welding (MAW)

Emissions/lb. of stick/wire

Metrics data will be recorded periodically as specified in the Process Management Plan. The results of the monitoring will be maintained and used to determine progress in achieving the goal of this BMP.

Process Guidance Elements for Metal Arc Welding

Testing and Evaluation Welding rod/wire The quantity of emissions released depends largely on the type of welding process used, its operating conditions and type of electrode utilized. Based upon on the choice of electrode and its diameter and composition, emissions are reduced or increased. For example, the fume generation rate for metal arc welding electrodes can vary from less than 10 to greater than 40 grams of fume per kilogram of deposited metal. Additionally, the composition of the fume will also be affected by the choice of electrode. It is important to evaluate the types of electrodes used to determine which electrodes will have the lowest fume generation rates and compositions that will contribute the least amount of the pollutant(s) of concern. Substrates being joined The workpiece composition also affects the quantity of fume released. Coatings on the workpiece generate organic and metallic fumes (e.g., galvanized coatings, cleaners, oils, paints, etc.), depending on the particular application. The workpieces should be evaluated to determine if they could be a significant contributor of the pollutant(s) of concern. If so, if may be beneficial to remove the coating from the weld area to reduce or eliminate the coating contribution to the fume. Shielding Gases Shielding gases have been shown to affect the fume generation rates (FGR) for various arc welding processes. Generally, carbon dioxide has been shown to increase the FGR over that of argon and helium. The types and mixtures of shielding gases used for specific jobs should be evaluated to ensure the proper gases and/or mixtures is utilized to reduce the FGR as much as possible.

Arc Welding Processes Welding is the process by which two metal parts are joined by melting the parts at the points of contact and simultaneously forming a connection with molten metal from these same parts or from a consumable electrode. In welding, the most frequently used methods for generating heat employ either an electric arc or a gas-oxygen flame. There are more than 80 different types of welding operations in commercial use. Of the various types of welding processes in use, electric arc welding is by far the most common. It is also the process that has the greatest emission potential. Particulate matter and particulatephase (fume) hazardous air pollutants are the major concerns in the welding processes. Most of the particulate matter produced by welding is submicron in size and, as such, is considered to be all PM-10. The elemental composition of the fume varies with the electrode type and with the work piece composition. Hazardous metals that have been identified in welding fume include manganese (Mg), nickel (Ni), chromium (Cr), cobalt (Co), and lead (Pb). Fume particulates can be deposited on surfaces throughout the work area or job site, where they may be exposed to rainfall and contribute to stormwater pollutant loading. As a rough guide, it may be noted that among the arc welding processes, SAW has the lowest fume formation rate. Then, in ascending order, come, GMAW, MAW and FCAW. Submerged Metal Arc Welding (SAW) produces an arc between a bare metal electrode and the work contained in a blanket of granular fusible flux. The flux submerges the arc and welding pool.

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Shipyard Stormwater Best Management Practice #5: Metal Arc Welding (MAW)

The electrode generally serves as the filler material. The quality of the weld depends on the handling and care of the flux. The SAW process is limited to the downward and horizontal positions, but it has an extremely low fume formation rate. Gas Metal Arc Welding (GMAW) is a consumable electrode welding process that produces an arc between the pool of weld and a continuously supplied filler metal. An externally supplied gas is used to shield the arc. Metal Arc Welding (MAW), also referred to as Shielded Metal Arc Welding (SMAW), uses heat produced by an electric arc to melt a covered electrode and the welding joint at the base metal. During operation, the rod core both conducts electric current to produce the arc and provides filler metal for the joint. The core of the covered electrode consists of either a solid metal rod of drawn or cast material or a solid metal rod fabricated by encasing metal powders in a metallic sheath. The electrode covering provides stability to the arc and protects the molten metal by creating shielding gases by vaporization of the cover. Flux Core Arc Welding (FCAW) is a consumable electrode welding process that uses the heat generated by an arc between the continuous filler metal electrode and the weld pool to bond the metals. Shielding gas is provided from flux contained in the tubular electrode. This flux cored electrode consists of a metal sheath surrounding a core of various powdered materials. During the welding process, the electrode core material produces a slag cover on the face of the weld bead. The welding pool can be protected from the atmosphere either by self-shielded vaporization of the flux core or with a separately supplied shielding gas. Electroslag Welding (ESW) is a welding process producing coalescence of metals with molten slag that melts the filler metal and the surfaces of the work pieces being welded. The weld pool is shielded by this slag, which moves along the full cross section of the joint as welding progresses. Electrogas Welding (EGW) is an arc welding process similar to ESW where auxiliary gas shielding around a flux cored electrode is utilized. This modification allows satisfactory welds in the vertical position on thinner plate in a single pass.

Welding Materials Welding Rod and Wire Welding rods and wires, more correctly termed welding electrodes, establish the arc and supply filler metal for the weld deposit. Additionally, the electrode introduces other materials into or around the arc to perform one or more other required functions, such as providing a blanket of shielding gas to prevent atmospheric contamination of the filler metal. The type of electrode used during welding operations will have a significant effect upon the type of pollutants generated and their emission rates, as most of the fume generated from welding is derived from the electrodes. Welding Flux Fluxes are granular mineral compounds that shield the molten weld poll from the atmosphere by covering the metal with molten slag (fused flux). Fluxes may to applied to the weld line as a powered material or incorporated in the electrode itself, such as flux core electrodes. Flux can have a significant effect on the fume generation rate, and therefore affect the type of pollutants generated, and their emission rates, from the welding operations. Shielding Gases The primary function of the shielding gas is to exclude the atmosphere from contact with the molten weld metal. This is necessary because most metals, when heated to their

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Shipyard Stormwater Best Management Practice #5: Metal Arc Welding (MAW)

melting point in air have a strong tendency to form oxides and nitrides, which result in weld deficiencies. Common shielding gases include argon, helium and carbon dioxide, which are often used together in mixtures for specific welding tasks. The type and mixture of shielding gases used are known to affect fume generation rate. Whenever possible, shielding gases that will reduce fume generation should be utilized. Welding power sources Either alternating current (ac) or direct current (dc) may be employed for shielded metal arc welding, depending upon the current supplied by the power source and the electrode selected. The primary function of the power source is to provide a suitable output voltage range, usually 20 to 80 volts, and provide a welding current, generally ranging from 30 to 1500 amperes. The volt-ampere characteristics of the power supply will have a significant effect on many welding parameters, including fume generation rate. Ceramic Tape Ceramic Backing Materials (CBM) consist of ceramic plates attached to tape that can be fastened to the back of the weld. CBM help produces smooth and homogeneous weldments by supporting the puddle and forming back beads during plane welding. This can significantly reduce the amount of electrode required to achieve the same length of weld, and therefore reduce the total amount of fume generated.

Production Process Variables Power Supply Voltage Fume generation rate is strongly affected by the power supply voltage. Most electrodes can be utilized over a voltage range. Unless restricted by other operational requirements, the lowest acceptable voltage should be utilized to reduce the FGR. By maintaining the welding angle close to perpendicular, the voltage can be reduced, which will likewise reduce the fume emission. Power Supply Amperage For many types of arc welding processes and electrodes, an increase in current tends to increase the amount of fume generated. The operator should select the lowest recommended current and voltage that will provide quality welds. Shielding Gases The types and mixtures of shielding gases used during welding operations have been shown to affect the process fume generation rate. Where possible, the appropriate types and mixtures of gases should be utilized to minimize the FGR. Feed Rate/Travel Speed The feed rate of the electrode and the weld travel speed will affect both the rate and amount of fumes generated for each specific job. These production variables should be adjusted for their lowest FGR, while maintaining the quality of the weld. Control of Root/Grove Size (No information on this process)

Production Training Becoming a skilled welder requires substantial training to learn the various welding processes and the intricacies of the job. The integrating of training regarding the potential environmental effects of the welding process, as well as how to recognize and control the generation of pollutants from welding, into production training programs can result in a significant improvement in environmental performance. For example, the proper current, arc voltage, arc length, travel speed, and welding electrode angle can all be selected to reduce fume emissions. The skilled welder will pay close attention to all these variables to ensure low fume emissions and good weld quality.

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Shipyard Stormwater Best Management Practice #5: Metal Arc Welding (MAW)

Structural Welders and Pipe Welders Production welders will be the primary source of welding fume in the facility. Initial and refresher training to provide information on proper welding techniques to maintain the lowest possible FGR during operations could significant reduce potential pollutant loading. Fitters Fitters may be required to perform welding operations on a job specific basis. Initial and refresher training to provide information on proper welding techniques to maintain the lowest possible FGR during operations could significant reduce potential pollutant loading. Welding Supervisors Supervisors are required to ensure welding personnel perform their job tasks in accordance with required procedures, including environmental procedures. Supervisors require appropriate training to recognize potential environmental issues resulting from welding operations, and how to eliminate or minimize pollutant loading. Equipment Maintenance Poorly or improperly, maintained welding equipment is more likely to have higher fume generation rates than correctly maintained equipment. Those personnel that are responsible for equipment maintenance require training in how equipment performance can impact pollutant emissions, and how to correctly maintain the equipment to reduce pollutant loading.

Add On Controls Control measures can be utilized to reduce pollutant loading in stormwater and other environmental media. For welding operations, control measures often consist of some type of capture and collection system that prevents the fume from escaping the work area where it may be exposed to stormwater. Fume collectors Capture systems may be welding booths, hoods, torch fume extractors, flexible ducts, and portable ducts. Collection systems may be high efficiency filters, electrostatic precipitators, particulate scrubbers, and activated carbon filters. Area Ventilation/Filtration When welding in a confined space, area ventilation is often used to remove fume from the work space and reduce the potential for occupational exposure. While providing for the safety of the worker, area ventilation can disperse the welding derived pollutants into the environment. If the ventilation exhaust air is filtered prior to discharge, the potential pollutant loading can be significantly reduced. Containment Containment of the work area in which welding operations are conducted will allow the fume particulates to settle out, and to be captured and disposed of properly. Care to protect the workers within the containment from harmful levels of welding fume must be taken, if the containment option is utilized.

Clean-Up Cleaning Frequency Welding fume and dust that may be exposed to rain fall should be cleaned from the work area on a regular and frequent basis. Cleaning should never be accomplished by air blowing, which would only re-suspend the fume particles, where they may be transported to other areas that are exposed to rainfall. Cleaning should be accomplished using vacuums equipped with appropriate filters and/or wet cleaning methods that prevent the escape of the fume to the environment.

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