eTool : Lead: Battery Manufacturing – Maintenance | Occupational Safety and Health Administration

Text Version

Typical System Layout Low Volume/High Velocity with Chart

Typical system shown with piping sizes of 2 1/8" for 7" - 72,000 rpm Disc sander(2 1/8"), 2 1/8" for chipping hammer (2 1/2"), 2 1/8" for 6" - 10,000 rpm Cup stone grinder (3"), 2 1/8" piping for 6" X 1", 10,000 rpm Wheel grinder (3 1/2"), and 2 1/8" piping for Swing Frame grinder( 2 1/2"). Fittings are in parentheses following each machine type. All lines flow into 4" piping connected to primary separator, dust collector, with recommended automatic bag cleaner, and exhauster to atmosphere.

	cfm	I.D. Plastic Hose Size
Disk sanders 3-9 inch diameter	60-175	1 - 1.5
Vibratory Pad Sander - 4" X 9"	100	1.25
Router, 1/8" to 1"	80-100	1 - 1.25
Belt Sander, 3" - 4000 cfm	70	1
Pneumatic chisel	60	1
Radial Wheel Grinder	70	1
Surface Dye Grinder, 1/4"	60	1
Cone Wheel Grinder	90	1.25
Cup Stone Grinder, 4"	100	1.25
Cup Type Brush, 6"	150	1.5
Radial Wire Brush, 6"	90	1.25
Hand Wire Brush 3" X 7"	60	1
Rip Out Knife	175	1.5
Rip Out Cast Cutter	150	1.5
Saber Saw	120	1.5
Swing Frame Grinder	380	2.25
Saw Abrasive 3"	100	1.25

System Notes:

Bell and socket, smooth - flow type tubing and fittings should be used throughout the system. When system is used for vacuum cleaning of abrasive materials, schedule Nol40 pipe and cast iron drainage fittings, or heavier, should be used in place of tubing.

From American Conference of Governmental Industrial Hygienists (ACGIH®), Figure VS-40-20, Industrial Ventilation : A Manual of Recommended Practice, 23^rd Edition. Copyright 1988. Reprinted with permission.

Text Version

Hygiene Facility

Hygiene facility floor plan:

Street
Side
Entry

(A)

Street Side Locker Room

(B)

Storage Lockers

Hand Washing Stations

(J)

Lunchroom
(K)

Vending Machines

Work Clothes Vacuum Station(I)

Plant side Entry (E)

Clean Issue

Dirty Turn-in

Restroom
(F)

Cloak Room (G)

Shoe Cleaning Machines
(H)

Laundry

Showers

(C)

Plant side Locker Room (D)

Autoshower (N)

Facility Function/Description:

The facility can be entered from the street at only one point. (A)
Street clothes are removed and clean work clothes, hardhat, and respirator are issued and donned in the street side locker room. (B)
The employee passes through a one-way turnstile in order to get to the plant-side locker room. (C)
The employee dons work boots and other safety gear in the plant-side locker room where they are stored. (D)
There is only one entry to the plant. (E)
The restroom just inside the cloak room is readily accessible during working hours. (F)
The cloak room provides a place to store coats, hardhats, gloves and respirators during break periods. (G)
During lunch break the employee first cleans his boots at the shoe cleaning machines (H), leaves coat and equipment in the cloak room (G), vacuums off his clothes at the vacuum stations (I), proceeds to the hand washing station where he thoroughly washes his hands (J), and finally enters the lunch room. (K)
At the end of the shift the procedure is as follows: the employee cleans shoes (H), removes contaminated clothing in the plant side locker room (D), stores boots, etc. in plant-side lockers, turns in dirty work clothes, hardhat and respirator to laundry (L), and proceeds to the showers. (M) He then must pass through an automatic shower (N) to return to the street-side locker room (B), where he dresses and leaves the facility. (A)

Lead: Battery Manufacturing » Maintenance

View larger image of workbench

Maintenance personnel are at risk of exposure to lead fumes and dust during maintenance operations involving equipment that is contaminated with lead. Appropriate PPE should be provided and work practices should be followed when performing maintenance on this equipment. There are recommended engineering and work practice controls to minimize employee exposure in the following situations:

Maintaining or moving contaminated equipment
Working in shops
Preventive maintenance program

Maintaining or moving contaminated equipment

Potential Source of Exposure

Maintenance shop personnel may be exposed to lead dust when servicing and handling equipment that is contaminated with lead.

Possible Engineering and Work Practice Controls

Decontaminate equipment prior to servicing by vacuum, water spray, or mechanical removal such as scraping or brushing in conjunction with local exhaust ventilation.

Working in shops

Potential Source of Exposure

Exposure to lead may occur when working on contaminated equipment in the maintenance shop. (Figure 1)

View larger image of hood for cup type surface grinder and wire brushes

Possible Engineering and Work Practice Controls

Provide a ventilated work bench.
Provide exhaust ventilation with HEPA filters.
- Flexible Exhaust Connections
- Workbench
Decontaminate equipment using vacuum, water spray, or mechanical removal such as scraping or brushing in conjunction with local exhaust ventilation.
Provide low volume and high velocity ventilated hand tools.
- Typical System Low Volume/High Velocity Diagram
- Hood for Cup Type Surface Grinder and Wire Brushes
Provide Laminar Flow (Supplied Air) Islands at work stations.
- Supplied Air Island
Provide wash-up sink for employees in the shop.
Keep surfaces free of lead contamination as much as possible.
Use local exhaust ventilation on torch.
- Ventilated Torch
Ensure that all shop vacuums are equipped with HEPA filters capable of removing lead.
Empty vacuums in a manner that minimizes the reentry of lead into the shop.

View larger image of ventilated torch

Preventive maintenance program

A well-designed system and a continuing preventive maintenance program are key in preventing and controlling ventilation system problems.

Elements of a Good Maintenance Program

Establish a safe place to file drawings, specifications, fan curves, operating instructions, and other papers generated during design, construction, and testing.
Establish a program of periodic inspection.
- The types and frequencies of inspections depend on the operation of the system and other factors.
  - Daily: Visually inspect hoods, ductwork, access and clean-out doors, blast gate positions, hood static pressure, pressure drop across air cleaner, and verbally communicate with users ("How is the system performing today?").
  - Weekly: Check air cleaner capacity, fan housing, pulley belts.
  - Monthly: Check air cleaner components.
  - See Example Checklist.
  A quick way to check for settled material in a duct is to take a broomstick and tap the underside of all the horizontal ducts. If the tapping produces a "clean" sheet metal sound, the duct is clear. If the tapping produces heavy, thudding sounds, there may be settled dust in the duct.
Establish a preventive maintenance program.
- Certain elements of any ventilation system should be checked on a regular schedule and replaced if found to be defective.
- See Example Checklist.
- OSHA Technical Manual: Ventilation Investigation. OSHA (1992), 26 pages. This manual describes the use of supply and exhaust ventilation to control emissions, exposures, and chemical hazards in the workplace.
Provide worker training.
- Workers need to be trained about the purpose and functions of the ventilation system. For example, they need to know how to work safely and how to best use the ventilation system. Exhaust hoods do little good if the welder does not know that the hood must be positioned close to the work.
Keep written records.
- Maintain written documentation, not only of original installations but also of all modifications as well as problems and resolutions.

Lead: Battery Manufacturing eTool

Lead: Battery Manufacturing » Maintenance

Maintaining or moving contaminated equipment

Working in shops

Preventive maintenance program