Electromagnetic Fields (EMF) in the welding …

1 Prepared by TWI Ltd for the Health and Safety Executive 2014 Health and Safety ExecutiveElectromagnetic Fields (EMF) in the welding environmentRR1018 Research ReportGeoff Melton and Rob ShawTWI LtdGranta ParkGreat AbingtonCambridge CB21 6 ALThe Electromagnetic Fields (EMF) Directive (2013/35/EU) was adopted in June 2013. Member States are required to bring into force any laws, regulations and or administrative provisions necessary to comply with the Directive by July 1st, 2016. This research report considers various types of welding and the requirements of the report provides:n A review of available literature using the TWI Weldasearch database and other sourcesn Measurements of the EMF emissions welders may be exposed to during the welding processesn Understanding where welding fits in with the requirements of the EMF Directive n A proposal for an EMF emission risk assessment procedure n Guidance on compliance for the welding industryThis report, and the work it describes, were jointly funded by HSE and TWI Ltd.

2 Its contents, including any opinions and/or conclusions expressed, are those of the authors alone and do not necessarily reflect HSE policy. Electromagnetic Fields (EMF) in the welding environmentHSE BooksHealth and Safety Executive Crown copyright 2014 First published 2014 You may reuse this information (not including logos) free of charge in any format or medium, under the terms of the Open Government Licence. To view the licence visit , write to the Information Policy Team, The National Archives, Kew, London TW9 4DU, or email images and illustrations may not be owned by the Crown so cannot be reproduced without permission of the copyright owner. Enquiries should be sent to iii Contents Executive Summary Background Overview Approach to Measurement Results Conclusions 1 Introduction 1 2 Action Levels 1 3 welding Processes 2 4 Number of welding Operators 6 5 Literature Review 6 6 Measuring Equipment 6 7 Assessment Procedure 7 General 7 Measurement positions 7 Measurement procedure 8 Low action levels and limb action levels 8 8 Measurements 9 9 Summary of Results 9 Arc welding processes 9 Resistance welding processes 9 Single phase AC resistance welding 9 Medium frequency resistance welding 9 Stud welding 9 Magnetic particle inspection (MPI)

3 9 Induction heating 10 10 Implications for Risk Assessments 10 11 Guidance to Industry 10 Table 1 Figures 1-2 Appendix A: Literature review Appendix B: Measurements Appendix C: EMF emission risk assessment procedure iv Executive Summary Background The new European Physical Agents Electromagnetic Fields (EMF) Directive (2013/35/EU), was published in June 2013 and will come into effect on 1 July 2016. It requires employers to limit workers exposure to EMFs in the workplace. The Directive contains technical Annexes, which provide action levels (ALs) and exposure limit values (ELVs). Meeting these values can be used as one way to demonstrate compliance with the Directive. Action levels can be measured directly with an appropriate meter but most ELVs require computer modelling or calculations to make the assessment.

4 Concerns have been raised that this Directive may have an impact on companies using welding processes. In particular, the major impact may be on those using arc and resistance welding , where the welding currents are high and the operator may be close to the equipment. Other processes, in the welding industry, which may also lead to relatively high exposures, are induction heating, stud welding and magnetic particle inspection. Mechanised variants of the above processes should not in general expose the welder to significant EMFs. Overview The report provides: A review of available literature using the TWI Weldasearch database and other sources. Measurements of the EMF emissions welders may be exposed to during the welding processes.

5 An understanding of the impact that the EMF Directive may have on welding . A proposal for an EMF emission risk assessment procedure. Guidance on compliance for the welding industry. Approach to Measurement Measurements of the magnetic field in positions where a worker is likely to stand were carried out for the following processes. Pulsed MIG/MAG welding . AC square wave TIG welding . Single-phase AC resistance welding . Medium frequency resistance welding . Magnetic particle inspection (MPI). Stud welding . Induction heating. Measurements were made using a NARDA ELT-400 instrument, which measures the magnetic field over a frequency range of 1Hz to 400kHz. This instrument displays the field in absolute units (tesla, T) and as a percentage of the low AL.

6 For comparison with the high and limb ALs the waveform was passed through a digital filter, based on the weighted peak method of assessment. welding parameters were chosen as being typical of those used with the equipment for a range of applications. Results For arc welding processes operating in DC mode the low ALs were not exceeded even in situations where the workers were in very close proximity to the magnetic field . However, for AC and pulsed arc processes higher magnetic Fields were measured. Although the limb AL was not exceeded for hand held torches, close to a bent welding cable the field to which the welder may be exposed, was found to approach the low AL. v Due to the much higher welding current used for resistance welding processes, the Fields to which welders may be exposed were found to be much higher than for arc processes and exposure is very dependent on welder position.

7 For equipment operating at mains frequency, it is possible the low AL could be exceeded and if the welder is holding components close to the electrodes hand exposure may also exceed the limb AL depending on welding parameters. For medium frequency equipment (typically 2kHz), the magnetic field at positions up to 500mm from the electrodes, is likely to exceed the low AL when using typical operating parameters. Closer to the electrodes, the high AL and limb AL are also likely to be exceeded. There are many variants of the stud welding process, but for the capacitive discharge variant tested, the field was found to significantly exceed the low AL at positions normally occupied by the welder.

8 Magnetic particle Inspection (MPI) is a widely used technique for detecting cracks in welds. For standard equipment, the external magnetic field was found to be low, but techniques for inspecting large components may result in the inspector being exposed to Fields above the low AL. Induction heating is used for brazing and pre-heating components before welding . Typically, for brazing the field was found to be below the low AL, but for pre-heating large components the ALs may be exceeded. The field is very dependent on position and the geometry of the component. Conclusions The work carried out in this project has shown many of the commonly used welding processes should not expose welders and operators to magnetic Fields in excess of the action levels (ALs).

9 Some process options may lead to the action levels (ALs) being exceeded. If the low ALs are exceeded, it is difficult to assess against the high ALs and the limb ALs because direct reading instruments are not commercially available. Furthermore, compliance to the ELVs can only be demonstrated by calculation or modelling which requires a suitable expensive software package. This work has shown that the resistance welding processes are most likely to be above the ALs. However, many exposures may be borderline or just exceed the ALs and simple measures may reduce workers exposure. Simply moving further away from the electrodes can solve the problem, so moving a foot switch, providing a guard or changing the operator s position may be sufficient.

10 However in some cases, more elaborate measures may be required such as holding components in a fixture, rather than by hand or using a robot to hold components whilst welding takes place. Whilst the use of robot welding lines reduces operator s exposure to EMF, companies need to ensure they carry out an assessment for all potential exposure scenarios, such as maintenance operations, training and operation of repair stations. However, it is worth noting that showing EMF exposure is below the action levels is only one way to demonstrate compliance to the Directive. The measurements, information and risk assessment procedures outlined in this report could be used by employers who undertake welding activities, to help them with their risk assessments and work towards compliance.