FOR BETTER WORK AND ENVIRONMENTAL  SAFETY

Thermal Spray is a safe process when operators are trained and knowledgeable about the specific processes and materials, and the equipment has been installed and maintained according to the manufacturers' recommendations. MEC recommends enrollment in training courses offered by the equipment supplier to obtain theoretical background and practical experience in the various thermal spray processes. For additional information regarding training or equipment maintenance, please contact mecpl@sancharnet.in or MEC Service Engineer.

It is recommended that all personnel connected with thermal spraying become familiar with the safety practices outlined in this web site as well as the established standards and regulations which have been set by local, state and federal health officials (i.e. OSHA). All regulations should be thoroughly read and understood to ensure proper compliance.

There are several basic precautions for thermal spraying which should always be observed. These include: good housekeeping, proper material/gas storage and handling practices, use and maintenance of equipment, operator training, sufficient exhausting of gases and fumes, and personal protective equipment (PPE) for skin ears, eyes and breathing (respirator) protection.

In the following Sections you will find references to many safety standards, regulations, and publications (the latest edition is always implied). This is not intended to be a complete and comprehensive list. The specific recommendations given may only be valid in certain locations. All users of thermal spray equipment and processes must become familiar with and obtain the necessary information to safely operate their equipment at their location. In Section 6 of this document you will find additional references and links to safety Standards and Regulations around the world.

All safety features and ergonomic principles have been considered in the design and manufacturing of the systems to keep the operator comfortable and safe as well as the coating environment.

General: It is a completely safe process when performed by a capable operator with proper understanding of flame spraying practices, knowledge of the equipment, care in operation, and one who follows the recommended precautionary measures. The possibility of hazards can be isolated by proper handing of high pressurized fuel gases and hose connections.

THERMAL SPRAY equipment has been expressly designed for HVOF spraying. Not intended for any other purpose such as welding, soldering, brazing and their likes.

Reduction of fire & explosion hazards: The stream of sprayed metal is hot. Always point the lighted gun towards the job. Carelessness in pointing the gun at paper or oily rags can result in fire. Special care should be taken to protect the hoses from spray stream.

Gases: A regular inspection is required for all gas equipment such as Fuel gas, Oxygen and airlines, compressors, regulators, etc. for leaks and loose connections. The backfire of the spray gun can be prevented by using pure gases and regular checking of nozzles and air caps.

Equipment maintenance: Total maintenance schedule and procedure has been described in the Operation Manuals and we recommend them strongly for safe and long serviceability of the system.

Metal dusts: The greatest care should be used in handling to minimize the danger of the dust explosion resulting from flame spraying, adequate ventilation must be provided for spray booths and other confined spaces, to prevent the accumulation of fumes and dust. Good housekeeping in the work area is essential. Inspect and clean regularly to assure that there is no potentially dangerous accumulation of dust. All types of dust having considerable calorific value can be explosive. This dust includes flour, starch, hard rubber dust, wool flour, aluminum dust and the dust of other metals. Aluminum and magnesium dusts are particularly hazardous. The dust must be wetted down and remain immersed in water. Accumulation of dry or partially wet dust should not be permitted. A MEC-SPRAY BOOTH is recommended to fulfill the requirements of the dust collection of system. All closed collectors should be provided with blow out holes or relief panels. All fans, pipes, dust arresters motors should be electrically grounded.

Gas cylinder precautions: Charged gas cylinders are potentially dangerous. Never put a gas cylinder in hazardous position. Keep cylinders away from heat and moisture. Always chain them to keep fro toppling. Put the valve caps on the cylinders when they are not connected for use. Do not hang a flame spray gun or its hoses on regulators or cylinder valves as a fire or explosion may result.

Flashback Arrestors

A flashback occurs when a mixture of fuel gas and oxygen combine and burn within the hose. The resulting flame travels towards the gas source at a very high speed and can result in a fire or explosion in either or both the oxygen or fuel gas cylinders. Flashback arrestors should be fitted to the regulators on both gas cylinders. The common reasons for a flashback are:

A flashback has two components, the flame front and a pressure wave. When the flame front enters a flashback arrestor, it passes first through a fine or closed sintered metal flame filter. This absorbs the heat of the flame thus "quenching" it (extinguishing the flame).

Once the flame is put out, it also is necessary to cut off the gas supply. The second element of a flashback, the wave, causes a pressure plate to be lifted causing the cutoff valve to operate. Depending upon the model and type of flashback arrestor, a "pop-up" button or lever may indicate that the cutoff valve has been activated.

Flashback arrestors must only be used with the gas that they are labeled for. Oxygen flashback arrestors have been specially de-greased.

Leak Checks

Please refer to your MEC equipment manual or contact MEC Service Engineer for specific procedures on leak checking.

Be sure to remove leaky or defective equipment immediately from service. Never attempt to repair gas regulators; regulators must be serviced by qualified gas repair facilities. Your local gas supplier can provide a list of qualified repair stations.

Eye protection is required for all spray equipment due to the presence of ultraviolet and infrared radiation. All eye and face protective equipment must be in accordance with OSHA 29 CFR 1910.133.

Eye protection is also necessary to protect from flying or airborne matter such as dust or powder residue.

Noise protection:

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