Design, Operation and Maintenance of

Local Exhaust Ventilation Systems

GUIDELINES ON
2



1 Introduction
Legal requirements
Scope

2 Exhaust Hood
General
Capture velocity
Specific hood design
Hood construction

3 Ducting System
General
Duct construction
Duct velocity
Branches, elbows and transitions
System details
System resistance and balance
4 Air Cleaning Equipment
General
Classification and selection
5 Exhaust Fan
General
Fan installation
Fan capacity and static pressure
6 Stack
General
7 Replacement and Re-circulated Air
General
Rate of supply
Makeup air system details
Recirculation
8 Operation and Maintenance
General
Table of Contents
3
Operation
Maintenance
9 Testing
General
Measuring static pressure
Measuring airflow in ducts

10 Annexes
Annex 1: Capture velocities
Annex 2: Metal thickness and classification
Annex 3: Design duct velocities
Annex 4: General classification of particulate collectors
Annex 5: Comparison of pollution control equipment
Annex 6: Sample visual inspection checklist
Annex 7: Pitot traverse diagrams

4


This set of Guidelines on Design, Operation and Maintenance of Local Exhaust
Ventilation Systems provides information on good practices related to the design,
fabrication, operation, testing and maintenance of local exhaust ventilation systems used
for removal of airborne contaminants.

It was prepared by the Occupation Safety & Health Division, Ministry of Manpower in
collaboration with the Department of Mechanical Engineering, National University of
Singapore in 2003. The Guidelines updated and expanded the first edition on Design
Guide for Local Exhaust Ventilation Systems in Factories, which was prepared by the
then Industrial Health Division of the Ministry of Labour in 1983.

It is intended for use by ventilation system designers, facility engineers, safety and health
professionals, plant maintenance personnel, and persons having responsibility for
ventilation system design, fabrication, operation, testing and maintenance.

The guidelines were endorsed by the Committee on Management of Chemical Hazards.
Suggestions for improvement of the guidelines are welcome and should be sent to
Occupational Safety and Health Division, Ministry of Manpower, 18 Havelock Road,
#03-02 Singapore 059764, or e-mailed to mom_oshd@mom.gov.sg

In preparing these guidelines, reference was made to the following publications.

1. Industrial Ventilation. A Manual of Recommended Practice. American Conference
of Governmental Industrial Hygienists. 23
rd
Edition 1998.

2. Guide for Testing Ventilation Systems. American Conference of Governmental
Industrial Hygienists. 1991.

3. American National Standard - Fundamentals Governing the Design and Operation of
Local Exhaust Ventilation Systems. American Industrial Hygiene Association. 2001.

4. Air Pollution Engineering Manual. Air & Waste Management Association. 2
nd

Edition 2000.

5. Design of Industrial Ventilation Systems. John L. Alden and John M. Kane. 5
th

Edition 1982.

6. Industrial Ventilation Workbook. D. Jeff Burton. 4
th
Edition 2001.

7. Industrial Ventilation. A Self-Directed Learning Workbook. D. Jeff Burton. 4
th

Edition 1997.

8. Handbook of Ventilation for Contaminant Control. Henry J. McDermott. 2
nd
Edition
1985.
Preface
5



Local exhaust ventilation systems are widely used to control toxic gases, vapors,
dusts, fumes and mists from various industrial operations and processes. A proper
design of an exhaust ventilation system is necessary for the effective removal of
airborne contaminants that would otherwise pollute the work environment resulting
in health hazards, or nuisance, or cause air pollution.

A local exhaust ventilation system usually consists of a number of separate exhaust
hoods applied to several different operations and connected by a system of branch
and main ducts to a central air cleaning device and common exhaust fan and
discharge stack to the outside atmosphere. Each of these components requires
separate consideration in the design of the overall system.


Legal requirements

Ventilation and removal of dust, fumes, etc are required under sections 14 and 59 of
the Factories Act respectively.

Section 14(3) stipulates that where gases, vapours or other impurities are generated
in the course of any process or work carried out in a workplace which may be
injurious to health, effective and suitable ventilation shall be provided for securing
and maintaining the circulation of fresh air in the workplace, to render harmless so
far as is practicable, all such gases, vapours or other impurities.

Section 59(1) stipulates that where any process or work carried on in any workplace
is likely to produce or give off any toxic, irritating or offensive dust, fume or other
contaminants, all practicable measures shall be taken to protect persons employed
in the workplace against inhalation of the dust, fume or other contaminants; and
prevent their accumulation in the workplace.

Section 59(2) specifies that the measures to be taken shall, where appropriate,
include providing local exhaust ventilation to remove the dust, fumes or other
contaminants at their sources of emission.

Section 59(3) states that the local exhaust ventilation system shall be so designed,
constructed, operated and maintained that dust, fume or other contaminants are
safely and effectively removed at the source of generation and not dispersed or
scattered in the surrounding air.




1. Introduction
6
Scope

This set of Guidelines on Design, Operation and Maintenance of Local Exhaust
Ventilation Systems sets minimum requirements for the design and fabrication of
industrial LEV systems used for the prevention and reduction of person exposure to
harmful airborne substances in the work environment. It establishes requirements
for the operation, testing and maintenance of LEV systems to assure continuous and
satisfactory functioning of the systems. It also establishes requirements for
replacement and re-circulated air.

(a) LEV system designs and specifications should as far as is practicable conform
to the requirements of these guidelines, or to other standards of good practice
equal to or more stringent than these guidelines.

(b) Persons designing, testing or maintaining an LEV system shall be qualified by
training and / or experience to perform the job.





General

(a) Exhaust hoods should be designed to effectively contain, receive or capture air
contaminants.

(b) Enclosing hoods should as far as possible be used to totally enclose emission
sources. If this is not feasible, partial enclosures using baffles or flanges to
increase hood efficiency should be considered.

(c) Exterior or capture hoods should be placed as close to emission sources as
possible.

(d) Exhaust hoods should be designed and located such that the contaminants are
removed from the breathing zone of persons at or near the hoods.

(e) Exhaust hoods should be placed away from the vicinity of any turbulent air
movement.

(f) Exhaust hoods should be designed, placed and operated to ensure even air flow
into the hoods for consistent and reliable emission control.





2. Exhaust Hood
7
Capture velocity

(g) Hood design should consider the capture or control velocity, flow-rate required
for optimum performance, and hood static pressure.

(h) An adequate control or capture velocity should be selected to capture the
contaminated air by causing it to flow into the exhaust hood. The recommended
range of capture velocities is appended in Annex 1.

(i) Hood flow-rate can be determined by theoretical or empirical calculation.

(j) Hood static pressure can be determined from hood entry loss factor which can
be obtained from manufacturers or suppliers of pre-built hoods or most
ventilation technical handbooks.

(k) Flanges or baffles should be provided wherever possible to eliminate airflow
from contaminant-free zones. The flange width should be equal to the square
root of the hood opening area.

Specific hood design

(l) Specific hood design and operating criteria can be found in the ACGIH
Industrial Ventilation Manual.

Hood construction

(m) Hoods should be at least 2 gauges heavier than the connecting duct, free of
sharp edges and bends, and reinforced for stiffness.

(n) A tapered transition piece between the hood and the exhaust duct should be
provided if possible.

(o) For cases where air temperature and corrosion problems are not severe,
galvanized sheet metal could be used to construct hood.

(p) For high temperatures of up to 480 C and over 480 C, black iron and stainless
steel could be used respectively. For corrosive gases and vapors, corrosive
resistant metals, polyvinyl chloride (PVC) or other plastics and coatings could
be used.

(q) A real-time hood performance monitor (e.g. a static pressure tap with
manometer) should be provided if failed hood performance could result in
hazardous conditions for persons using the hood.



8



General

(a) The equipment of the exhaust system should be located to permit, as far as
possible, a symmetrical layout of pipes about the central fan, to minimize
inequality in airflow resistance in the branches.

(b) The shortest lengths of straight ductwork should be used; long runs of small
diameter duct, and all unnecessary elbows, tees or entries should be avoided.

(c) Exhaust duct takeoff should, wherever possible, be located in the line of normal
contaminant travel.

(d) Ductwork should be located so that it is readily accessible for inspection,
cleaning and repairs; ductwork should be protected against external damage.

(e) For large and shallow hoods, multiple takeoffs could be used to attain the
desired distributions of exhaust airflow. Interior baffles or filter banks could
also be used to attain satisfactory air distribution.

Duct construction

(f) All exhaust system should be constructed of new materials and installed in a
permanent and workmanlike manner. Duct supports of sufficient capacity
should be provided to carry the weight of the system.

(g) The interior of all ducts should be smooth and free from obstructions, especially
at joint, elbows, and bends.

(h) Round duct should be used for the construction of the exhaust system.
Rectangular ducts, if used, should be as square as possible.

(i) Ducts should be constructed of galvanized sheet steel riveted and sealed, or
black iron welded, flanged or gasketed, except where corrosive gases or mists or
other factors render such metals impractical. Galvanized construction is not
recommended for temperatures above 200
o
C.

(j) For corrosive conditions, corrosive resistant metals, polyvinyl chloride or other
plastics or coatings could be used for duct construction.

(k) The actual metal thickness for round industrial ducts will vary with the diameter
of the duct, the concentration and abrasiveness of the contaminants, static
pressure, reinforcement, and span between supports. The recommended range of
3. Ducting System
9
metal thickness for ducts of local exhaust systems for non-corrosive
applications is appended in Annex 2.

Duct velocity

(l) Duct velocities should be sufficient to prevent the settling of dry aerosols. The
recommended minimum duct velocities are appended in Annex 3.

(m) When condensable vapors are to be exhausted, the effects of cold temperatures
on the exhaust duct should be considered and provisions should be made to
prevent unwanted or uncontrolled condensation.

Branches, elbows and transitions

(n) All branches should enter the main duct at gradual expansions at an angle not
exceeding 45
o
and preferably 30
o
or less. Connections should be to the top or
side of the main and directly opposite each other.

(o) Elbows and bends should be at a minimum of 2 gauges heavier than straight
length ducts of equal diameter and have a centerline radius of at least 2 and
preferably 2.5 times the pipe diameter.

(p) Transitions in mains and sub-mains should be tapered in duct enlargement and
contraction. The taper should be at least 5 units long for each unit change in
diameter.

(q) The smaller branches should enter the main near the high-suction end, closer to
the fan inlet.

System details

(r) Static pressure losses throughout the LEV system should be determined before
fans are selected.

(s) The duct design should allow for vibration and expansion. Flexible connection
should be made between the duct and the fan or air-cleaning unit.

(t) Clean out opening should be provided in horizontal runs of ducts carrying dust-
laden air and, especially, near elbows and junctions.

(u) Where condensation may occur, the duct system should be liquid-tight and
provisions made for proper sloping and drainage.

(v) Where blast gates are used for airflow adjustment or system balance, they
should be placed near the connection of branch to main duct, and means of
locking should be provided after the adjustments have been made.
10

(w) The diameter of the main duct should be approximately equal to the fan inlet
diameter.

(x) Hoods and ductwork should not be added to an existing system unless such
additions were specifically provided for in the original design or such additions
are approved by a person qualified to perform system design.

System resistance and balance

(y) In a multiple branch system, the desired airflow between the branches should be
properly distributed by Static Pressure Balance method. Blast Gate Adjustment
method for balancing an exhaust system is not encouraged. A balanced design
would usually provide for the most effective local exhaust ventilation system.
With a balanced design method, the ventilation system is designed to operate at
desired flows without further balancing after construction, i.e., it is balanced on
paper during design.




General

a) Air cleaning equipment should be compatible with all the components of the
local exhaust ventilation system.

b) Fire safety and explosion control must be considered when designing or
selecting an air-cleaning device.

c) Emission rate, capacity, and resistance of the air cleaner should remain as
constant as possible throughout its daily operating cycle and be nearly
independent of entering dust, fume, or vapor concentration.

Classification and selection

(d) The selection of air cleaning equipment is based on the characteristics of the air
/ gas stream, and the nature and quantity of the contaminants. Air cleaning
equipment and devices are classified and compared in Annexes 4 and 5.

(e) The degree of outflow air cleanliness should satisfy the National Standards for
Air Pollutants prescribed by the Pollution Control Department of the National
Environment Agency (NEA).

(f) Handling and disposal of collected materials or effluents from the air cleaning
equipment should meet NEAs requirements and should not create a hazard to
persons handling the materials.
4. Air Cleaning Equipment
11





General

(a) An exhaust fan must be selected to produce the rate of airflow required by the
exhaust system. The flow must be developed against the total system resistance,
including pressure losses through the hoods, branch and main exhaust ducts and
accompanying fittings such as elbows, branch-main junctions as well as those
incurred through air cleaners and discharge piping.

(b) The exhaust fan should be located near the middle of an array of exhaust hoods
rather than at the end if possible; high static pressure or suction branch ducts
should be located near the fan.

(c) The exhaust fan should be located downstream of the air cleaning equipment to
protect it against any corrosive action of the gas or vapours or any abrasive
action of the dust which is being collected, and as close to the discharge point as
possible.

(d) The preferred location for an exhaust fan is outdoors, normally on the roof. Fan
location should be chosen such that noise would not be a problem.

(e) A straight duct section of at least 6 equivalent duct diameters and 3 equivalent
duct diameters should be used when connecting to the fan inlet and outlet
respectively before any bend or fittings. Where this is impracticable due to
space constraints, corrective devices such as turning vanes or flow dividers
should be used, or the associated pressure loss must be accounted for.

(f) Fan selection should consider long-term contaminant effects on the fan and the
fan wheel. Where severe conditions of abrasion or corrosion are present, special
linings or metals could be used in fan construction. Fan blades might need to be
cleaned periodically.

Fan installation

(g) A flexible sleeve or band should be incorporated onto the fan inlet and outlet
ducts to minimize vibration of the ductwork.

(h) Fan and motor should be firmly mounted on a sound foundation or structural
support. If vibration isolator supports are to be used, the fan and motor should
be mounted solidly to a common, rigid base and the vibration isolators placed
between the base and the structural support.

5. Exhaust Fan
12
(i) The noise level from the fan should not be more than 90 dBA and preferably be
below 85 dBA measured 1m away from the fan. Silencers may be installed on
the clean side of the system. However, silencers would impose additional
resistance, the loss for which must be accounted for in the design calculations.

(j) Safe means should be provided to allow the wheel of an exhaust fan to be
examined without removing the connecting ducts. This provision may be,
however, waived for smaller fans used in non-corrosive and non-dusty
atmospheres.

(k) When the exhaust systems are used to handle flammable gases or vapors or
combustible dust, the fan blades and casing should be made of non-sparking
material, and the motor should be placed outside the combustible region or be of
explosion-proof design. Electrical bonding and grounding should also be
provided for all fan parts.

Fan capacity and static pressure

(l) The fan must have a capacity not less than the sum of the originally estimated
airflow rates for all the exhaust hoods.

(m) A fan of the proper size and operating speed should be selected from the rating
table published by the fan manufacturer based on the airflow rate and static
pressure required.





General

(a) Exhaust stacks should be vertical and terminated at a point where height or air
velocity would preclude re-entry of the contaminated air into the work
environment.

(b) Weather cap on discharge stack is not recommended. Stackhead design should
be used.

(c) Local exhaust ventilation stack outlets should be sufficiently (3 m
recommended) above adjacent air intakes and / or roof lines if they are within
15 m of the stack.

(d) The stack outlet velocities should be high enough to prevent back-drafting.



6. Stack
13


General

(a) If the local exhaust system is utilized in space where there is no or inadequate
natural ventilation, makeup air should be supplied to the enclosed space so that
the pressure difference is always within 10%.

(b) Makeup air should be filtered at the air intake to protect ventilation system
equipment and to ensure that the makeup air is clean.

(c) A monitoring system should be provided to signal any malfunction of the
makeup air system if the malfunction could adversely affect the performance of
the local exhaust ventilation system.

Rate of supply

(d) To maintain a slight negative pressure in an area to control fugitive emissions
and/or prevent migration of contaminants to other areas of the plant or building,
the exhaust rate should be more than the supply rate but not more than by 10%.

(e) To maintain a slight positive pressure in an area to prevent intrusion of dust into
clean areas, the supply rate should be more than the exhaust rate but not more
than by 10%.

(f) In cases where the local exhaust ventilation systems vary the exhaust airflow
over time, the makeup air volume flow rate should track the exhaust airflow
rates to maintain proper pressure relationship.

Makeup air system details

(g) The supply air should be located such that clean air is first passed over the
people and then to the contaminated area, where it will be removed by the local
exhaust ventilation system. The flow should also be from normal temperature
areas to high heat process areas to provide some cooling.

(h) The makeup air intakes should be located so that no contaminated air from
nearby exhaust stacks or any sources of air contaminants is drawn into the
makeup air system.

(i) Makeup air should be introduced into the living zone of the area, generally
2.4 to 3.0 m from the floor.

(j) Supply air locations and velocities should be selected to avoid high velocity
drafts on hooded processes or on the workers themselves.

7. Replacement and Re-Circulated Air
14
Recirculation

Recirculation of exhausted air is usually discouraged, especially for systems
handling toxic contaminants or high concentrations of any material. However,
recirculation seems to be the only practical way of operating some of the larger
exhaust system as the cost of energy to condition the air can be very high.
Increasing energy consumption also makes recirculation more desirable for many
smaller exhaust systems. Recirculation may be deemed acceptable in some
circumstances under the following conditions:

(k) The physical, chemical and toxicological properties of the contaminants in the
air stream to be re-circulated must be identified and accessed. Exhaust air
containing substances whose toxicity is unknown or for which there are no
established permissible exposure levels should not be recirculated.

(l) The effects of a recirculation system malfunction must be considered.
Recirculation should not be permitted if a malfunction could result in exposure
levels that would cause permanent damage or significant physiological harm.

(m) The availability of an effective air cleaner must be determined. An air cleaner
capable of removing airborne contaminants to achieve acceptable workplace
concentrations must be available.

(n) The effects of minor airborne contaminants should be considered. Recirculation
should not cause a concentration of minor contaminants to reach an
unacceptable level.

(o) Recirculation systems should incorporate a monitoring system that gives an
accurate warning or signal capable of initiating corrective action or process
shutdown before harmful concentrations of the recirculated contaminants build
up in the workplace.





General

(a) Employees working with LEV systems and maintenance personnel responsible
for LEV systems should be instructed on the proper operating procedure and
reasons for the installation.

(b) Every individual testing, operating, maintaining and redesigning the local
exhaust ventilation system should have access to the most recently updated
plans and specifications for the local exhaust ventilation system.

8. Operation and Maintenance
15
(c) Lock-out, tag-out programmes for both electrical power sources and mechanical
energy sources should be established. Typically, the fan wheel should be locked
out during installation or maintenance of the fan.

Operation

(d) A programme of safe operating procedures based on the needs of the system and
the process should be established and maintained.

(e) No process or equipment on which the exhaust ventilation has been installed for
the protection of the employees should be operated when the exhaust system is
not functioning properly.

(f) Every local exhaust ventilation system handling particulate matter should be
operated with inlets to the system open unless the system was specifically
designed for safe operation with some inlets closed. Using dampers for any
reason except balancing and shutoff during maintenance is usually discouraged.

Maintenance

(g) A programme of scheduled maintenance tailored to the needs of the system
should be established. The responsibility for scheduled maintenance and
oversight should be entrusted to a single, qualified individual who should
maintain a logbook of maintenance for references.

(h) Manufacturers recommendations for the maintenance of local exhaust
ventilation system components should be included in the maintenance schedule.
The maintenance schedule, in general, should include the clearing of any
blockages in the ductwork and the cleaning of the air cleaning equipment on a
regular basis.





General

(a) Every ventilation system should be thoroughly inspected and tested upon
completion of installation to determine that its installation is in accordance with
the design specifications and drawings. The initial test should include
measuring the volumetric flow rate, fan static pressure, and fan speed, as well as
determining the pressure drops across air cleaning equipment and all fittings
and components. The initial test acts as a baseline for periodic maintenance
testing and rapid isolation of system failures when a malfunction occurs. The
test is also necessary to verify the setting of blast gates, fire dampers, and other
airflow control devices which may be part of the system.
9. Testing
16

(b) The test data should be compared with design specifications. If adjustments or
alterations are made to the system in order to meet the specifications or
performance criteria, the system should be retested.

(c) Visual inspections for physical damage (e.g. leaking or corroded duct) and
proper operation of components (air cleaner, exhaust fan, damper, etc) should
be carried out at least once a month. A sample of an inspection checklist is
appended in Annex 6.

(d) Periodic tests (including static pressure and airflow measurements) of at least
once every 12 months should be made throughout the life of the system to
ensure continuing performance. Tests should also be carried out whenever
major modifications are made to the system, or when complaints of poor
performance are made by operating personnel.

(e) The measured static pressures and volumetric flow rates should be compared
with that of the initial test. If corrections or alterations are made to the system, a
new initial test should be conducted to verify system performance.

(f) Makeup air system should be included in the local exhaust ventilation testing
procedure. As naturally or mechanically supplied air must be provided to the
workspace, the performance of the makeup air system should be tested with
adjustments for flow, direction, and supply air system components.

(g) All instruments used for testing must be calibrated, frequently if specified,
especially direct-reading meters as they are easily impaired by shock, dust, high
temperatures, and corrosive atmospheres.

(h) Records of testing and measurements should be kept.

Measuring static pressure

Static pressure can be measured by a vertical manometer, inclined manometer, Pitot
tube or other pressure measuring devices.

(i) For hood static pressure measurement, a static pressure hole of 12 mm diameter,
drilled at one pipe diameter away from the hood opening, should be provided at
each hood opening.

(j) Each branch and main duct should be provided with a 12 mm diameter static
pressure hole, drilled 7.5 diameters straight run downstream from the nearest air
disturbance such as elbow or bend, for static pressure measurement. If this is not
possible, then four holes should be drilled 90 degrees apart around the duct and
the static pressure values averaged.

17
(k) Static pressure holes should be provided for pressure measurement at both the
inlet and the outlet of the air-cleaning device. The resistance or pressure drop
across the air cleaning equipment should be determined and compared with the
manufacturers data for maintenance purpose.

(l) Static pressure holes should be provided for pressure measurements at both the
inlet and outlet of the fan.

Measuring airflow in ducts

Airflow rate in a duct is obtained by multiplying the air velocity and the cross-
sectional area of the duct. The air velocity is determined by the velocity pressure
which can be measured by Pitot traverse method.

(m) A Pitot traverse across the diameter of a duct should be performed to measure
airflow in the duct. The traverse should be made at a location of at least 7.5 duct
diameters downstream from any major disturbance such as damper, elbow or
branch entry. If the traverse is made less than 7.5 duct diameter, another
traverse at a second location should be made and checked if there is an
agreement within 10% of the readings obtained at the two traverses. If there is
an agreement, the average of the two readings should be used. Where the
variation exceeds 10%, a third location should be selected and the two airflows
in the best agreement averaged and used.

(n) For round ducts, two traverses across the diameter of the duct at right angles to
each other should be made. For ducts 15 cm in diameter or smaller, two 6-point
traverses should be made. For ducts 15 to 120 cm in diameter, at least two 10-
point traverses should be made. Above 120 cm or for smaller ducts where large
velocity variations are suspected, two 20-point traverses should be made. The
locations of the measuring points are selected such that the duct is divided into
equal annular areas, not equal distant points along the duct diameter. Refer to
Annex 7 for measurement locations.

(o) For rectangular ducts, the cross-section should be divided into a number of
equal areas and the velocity pressure reading is measured at the center of each
area. At least 16 readings should be taken, but the distance between measuring
points should not exceed 15 cm. Refer to Annex 7 for measurement locations.

(p) A Pitot tube cannot be used for measuring velocities less than 3.0 m/s.







18



Annex 1

Capture Velocities


Condition of Dispersion
of Contaminants

Examples
Capture
Velocity
m/s
Released with practically no
velocity into quiet air

Evaporating from tanks; degreasing 0.25 - 0.5
Released at low velocity into
moderately still air
Spray booths; intermittent container
filling welding, plating, pickling

0.5 - 1.0
Active generation into zone of
very rapid air motion
Spray painting in shallow booths;
barrel filling; conveyor loading;
crushers

1.0 - 2.5
Released at high velocity into
zone of rapid air motion

Grinding; abrasive blasting,
tumbling
2.5 - 10


In each category above, a range of capture velocity is shown. The proper choice of
values depends on the following factors.


Lower End Range Upper End Range

(1) Room air current minimal (1) Disturbing room air current
(2) Contaminant of low toxicity (2) Contaminants of high velocity
(3) Intermittent, low production (3) High production, heavy use
(4) Large hood large air mass in motion (4) Small hood - local control ones

10. Annexes
19
Annex 2

Metal Thickness and Classification

Classification of ducts for Local Exhaust Ventilation systems for noncorrosive
applications.

Class 1
Light duty for nonabrasive applications such as replacement air and
general ventilation.

Class 2
Medium duty for applications with moderately abrasive particulates
in light concentrations such as woodworking and grain dust.

Class 3
Heavy duty for applications with highly abrasive particulates in low
concentrations such as abrasive cleaning and sand handling.

Class 4
Extra heavy duty for applications with highly abrasive particles in
high concentrations such as canopying systems in heavy industrial
plants.



Range of Metal Thickness
Standard Gauge for Steel Duct
Diameter of Straight Duct Class 1 Class 2 Class 3 Class 4
100 mm to 200 mm 22-20 22-18 16 14
>200 mm to 450 mm 22-12 22-12 16-11 14-11
>450 mm to 760 mm 18-7 16-7 16-6 14-6
>760 mm 14-2 14-2 12-2 12-2





20


Annex 3

Design Duct Velocities


Nature of Contaminant Example
Design
Velocity
m/s

Vapours, gases, smokes All vapours gases & smoke 6.0 - 10.0

Fumes Zinc and aluminium oxide fumes 7.0 - 10.0

Very fine, light dust Cotton lint, wood, flour, litho
powder
10.0 - 12.5

Dry dusts and powders Fine rubber dust, Bakelite molding
powder dust, jut lint, cotton, dust,
shavings (light), soap dust, leather
shaving.
12.5 - 17.5

Average Industrial dust Sawdust (heavy and wet), grinding
dust, buffing lint (dry), wool, jute
dust, coffee beans, shoe dust, granite
dust, silica flour, general material
handling, brick cutting, clay dust,
foundry (general), limestone dust,
packaging and weighing asbestos
dust in textile industries
17.5 - 20.0

Heavy dusts Metal turnings, foundry tumbling
barrels and shakeout, sand blast dust,
wood blocks, hog waste, brass
turnings, cast iron boring dust, lead
dust
20.0 - 22.5

Heavy or moist dusts Lead dusts with small ships, moist
cement dust, asbestos chunks from
transite pipe cutting machines,
buffing lint (sticky) Quick-lime dust
22.5 & above


21

Annex 4

General Classification of Particulate Collectors



Control Device

Class

Force
Particle Diameter
for 90% Removal
in microns
Settling Chamber Mechanical Gravity

50
Impingement
Separator
Mechanical Initial Impingement 25
Cyclone
(Small Diameter)
Mechanical Centrifugal >5
Cyclone
(Large Diameter)
Mechanical Centrifugal 25
Bag house Filtration
Panel Filters Filtration
Inertial Impingement +
Electrostatic + Diffusional
>1
Mat Filters Filtration
Deep Filter Beds Filtration
Inertial Impingement +
Electrostatic + Diffusional
>1
Spray Chamber Scrubber
Packed Tower Scrubber
Inertial Impingement +
Electrostatic + Diffusional
10
Cyclone Scrubber Scrubber Inertial Impingement +
Electrostatic + Diffusional
1
Venturi Scrubber Inertial Impingement

25
Wet Inertial
(Mechanical)
Scrubber Inertial Impingement 5
Orifice Scrubber Inertial Impingement +
Centrifugal

5
Single-stage High
Voltage
Electrostatic
Precipitators
Electrostatic Attraction >1
Two-stage Low
Voltage
Electrostatic
Precipitators
Electrostatic Attraction >1





22
Annex 5

Comparison of Pollution Control Equipment


Device

To Control Advantages Disadvantages Costs Examples
Mechanical
Separators
Medium to
large diameter
particles
1) Low initial
cost
2) Simple
construction
3) Erase of
operation
4) Use as pre-
cleaners
1) Low
efficiency
2) Erosion of
components
3) Cannot
remove small
particles
4) Large space
requirements

Low initial
cost
1) Gravity
Chambers
2) Impingement
Separators
3) Cyclone
Collectors
Filtration
Devices
Dusts, fumes 1) High
collection
efficiency on
small particles
2) Moderate
power
requirements
3) Dry disposal
1) High costs
2) Large space
requirements
3) Must control
moisture and
temperature
of a gas
stream

High costs 1) Fabric Filters
2) Mat Filters
3) Ultra-filters
Wet
Collectors
High-
temperature,
moisture-laden
gases
1) Constant
pressure drop
2) Elimination of
dust removal
problems
3) Compact
design
1) Disposal of
waste water
may be
expensive and
troublesome
Moderate 1) Spray
Chambers
2) Cyclone,
Orifice,
Venturi
Scrubbers
3) Mechanical
Centrifugal
Collectors

Electrostatic
Precipitators
All sizes of
particles-even
very small
mists which
form free-
running liquids
1) High
efficiency
2) Dry dust
collection
3) Low pressure
drop
4) Can collect
mists and
corrosive acids
1) Often
requires pre-
cleaner
2) Large space
requirements
3) Cannot
collect some
high/low
resistivity
materials
4) High initial
cost

High initial
costs-low
operating &
low
maintenance
costs
1) Single-stage
Precipitators
2) Two-stage
Precipitators

23

Device

To Control Advantages Disadvantages Costs Examples
Gas
Absorbers
Highly
odorous,
radioactive or
toxic gases
1) Contaminant
solvent may
be recovered

1) High
equipment &
operating costs
2) Corrosion
3) Contamination
High
equipment
and
operating
costs

1) Fixed Bed
2) Regenerative
Combustion
Incinerators
Odours, plume
opacity,
carbon
monoxide,
organic
vapours
1) Capable of
reaching high
efficiency
operation

2) Catalytic
combustion
reduces NO
x

pollutants
1) Must burn
additional fuel
or add
catalyst

2) Incomplete
combustion
can further
complicate
original
problem

Vary
widely
depending
upon
application
1) Direct flame
2) Catalytic
combustion







24
Annex 6

Sample Visual Inspection Checklist

Exhaust Hood
Is there any physical damage such as corroded surfaces?
Is there any cross draft or turbulence air currents at the hood face?
Are the contaminants captured by the hood during normal operation?

Ducting System
Is there any physical damage such as dents or holes in the duct?
Is there any blockage in the duct by contaminants?
Are the damper or blast gate settings correct?

Air Cleaning Equipment
Is there any physical damage such as leakage?
Is the waste material handling satisfactory?

Exhaust Fan
Is the blade worn out or corroded?
Is the direction of rotation correct?
Is the rotation speed sufficient?
Is the fan belt slipping?
Is there any leakage at the flexible sleeve?
Is there excessive noise or vibration?

Stack
Is the stack exit velocity sufficient?
Is dispersion hindered in any possible way?

Makeup Air System
Is contaminated air recirculated?
Is the makeup air sufficient?
Is there any interference with the capture velocity?



25


Annex 7

Pitot Traverse Diagrams

































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10 Point Pitot Treverse in a
Circular Duct
6 Point Pitot Treverse in a
Circular Duct
Pitot Treverse Points in a
Rectangular Duct