CEN/TR 15339-6:2014

SLOVENSKI STANDARD
01-julij-2014
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Thermal spraying - Safety requirements for thermal spraying equipment - Part 6: Spray
booth, Handling system, Dust collection, Exhaust system, Filter
Thermisches Spritzen - Sicherheitsanforderungen für Einrichtungen für das thermische
Spritzen - Teil 6: Spritzkabinen, Handhabungssystem, Staubsammlung, Abluftsystem,
Filter
Projection thermique - Exigences de sécurité relatives au matériel de projection
thermique - Partie 6: Cabine de projection, Système de manipulation, Collecte de
poussière, Système d'évacuation, Filtre
Ta slovenski standard je istoveten z: CEN/TR 15339-6:2014
ICS:
25.220.20 Površinska obdelava Surface treatment
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

TECHNICAL REPORT
CEN/TR 15339-6
RAPPORT TECHNIQUE
TECHNISCHER BERICHT
May 2014
ICS 25.220.20
English Version
Thermal spraying - Safety requirements for thermal spraying
equipment - Part 6: Spray booth, Handling system, Dust
collection, Exhaust system, Filter
Projection thermique - Exigences de sécurité relatives au Thermisches Spritzen - Sicherheitsanforderungen für
matériel de projection thermique - Partie 6: Cabine de Einrichtungen für das thermische Spritzen - Teil 6:
projection, Système de manipulation, Collecte de poussière, Spritzkabinen, Handhabungssystem, Staubsammlung,
Système d'évacuation, Filtre Abluftsystem, Filter

This Technical Report was approved by CEN on 22 October 2012. It has been drawn up by the Technical Committee CEN/TC 240.

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania,
Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United
Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION

EUROPÄISCHES KOMITEE FÜR NORMUNG

CEN-CENELEC Management Centre: Avenue Marnix 17, B-1000 Brussels
© 2014 CEN All rights of exploitation in any form and by any means reserved Ref. No. CEN/TR 15339-6:2014 E
worldwide for CEN national Members.

Contents Page
Foreword .4
1 Scope .5
2 Normative references .5
3 Function of thermal spraying equipment for thermal spraying .5
3.1 General .5
3.2 Function and construction of a spray cabin .5
3.2.1 General requirements .5
3.2.2 Features of a spray cabin .6
3.2.3 Layout for a spray cabin or a thermal spraying equipment in the workshop .6
3.2.4 Ventilation and exhausting for the spray cabin .6
3.3 Equipment in the spray cabin .8
3.3.1 General .8
3.3.2 Function and description of the manipulating systems .8
3.3.3 Electrical equipment and installation .8
3.4 Extraction and filtering equipment .9
3.4.1 General .9
3.4.2 Dry extraction .9
4 Potential hazards . 10
4.1 General . 10
4.2 Mechanical hazards . 10
4.3 Electrical hazards . 10
4.4 Thermal hazards . 10
4.5 Fire and explosion . 10
4.6 Hazards generated by noise . 10
4.7 Hazards generated by radiation . 11
4.8 Hazards generated by spray materials and substances . 11
4.9 Hazards generated by neglecting ergonomic principles . 11
4.10 Human error, human behaviour . 11
4.11 Hazard of asphyxiation . 11
5 Safety requirements – protection measures . 11
5.1 General . 11
5.2 Protection measures from mechanical hazards . 12
5.3 Protection measures from electrical shock or other injury from the energy supply . 12
5.4 Protection measures from thermal attack . 13
5.5 Protection measures from fire and explosion . 13
5.6 Protection measures from noise outside the spray cabin in the workshop . 13
5.7 Protection measures from radiation . 14
5.8 Protection measures from attack by spray materials and substances. 14
5.8.1 General . 14
5.8.2 Control of the emission into the environment . 15
5.8.3 Pressure supervising of the filter system . 15
5.8.4 Precautionary measures for air recovery back into the spray cabin or workshop . 15
5.8.5 Cleaning the cabin . 15
5.8.6 Disposal of spray dust . 16
5.9 Protection measures from neglecting ergonomic principles . 16
5.10 Protection measures in the case of human error and human behaviour . 16
5.11 Protection measures when entering the spray cabin . 16
5.12 Safety related maintenance . 16
6 Requirements for manufacture, supply, operation, and maintenance . 17
6.1 Requirements for the manufacturer . 17
6.2 Requirements for the integrator . 17
6.3 Requirements for the user . 17
7 National rules . 18
Bibliography . 19
Foreword
This document (CEN/TR 15339-6:2014) has been prepared by Technical Committee CEN/TC 240 “Thermal
spraying and thermally sprayed coatings”, the secretariat of which is held by DIN.
Attention is drawn to the possibility that some of the elements of this document may be the subject of patent
rights. CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent rights.
According to the CEN-CENELEC Internal Regulations, the national standards organizations of the following
countries are bound to announce this Technical Report: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech
Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece,
Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal,
Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom.
1 Scope
This Technical Report specifies safety requirements of machines and equipment for thermal spraying, in this
case of spray booths, handling, dust collection, exhaust, and filter systems.
This Technical Report should be used in conjunction with the Technical Report CEN/TR 15339-1 which deals
with general aspects for design, manufacture, and/or put into service of machines or equipment and with the
responsibility to issue the CE Conformity Declaration.
2 Normative references
The following documents, in whole or in part, are normatively referenced in this document and are
indispensable for its application. For dated references, only the edition cited applies. For undated references,
the latest edition of the referenced document (including any amendments) applies.
EN 657, Thermal spraying - Terminology, classification
EN 12198-1, Safety of machinery — Assessment and reduction of risks arising from radiation emitted by
machinery — Part 1: General principles
CEN/TR 15339-1, Thermal spraying — Safety requirements for thermal spraying equipment — Part 1:
General requirements
EN ISO 10218-2, Robots and robotic devices - Safety requirements for industrial robots - Part 2: Robot
systems and integration (ISO 10218-2)
EN ISO 13849-1, Safety of machinery - Safety-related parts of control systems - Part 1: General principles for
design (ISO 13849-1)
EN ISO 15667, Acoustics - Guidelines for noise control by enclosures and cabins (ISO 15667)
EN ISO 60204-1, Safety of machinery — Electrical equipment of machines — Part 1: General requirements
EN 60974-10, Arc welding equipment - Part 10: Electromagnetic compatibility (EMC) requirements
3 Function of thermal spraying equipment for thermal spraying
3.1 General
The spraying processes are described in EN 657. Thermal spraying creates process related heat, fume, dust,
radiation and high levels of noise. Therefore thermal spraying systems are usually installed in firm enclosures.
They are designed to protect personnel and environment and to control and minimise the exposure of the
operator and others. Dust and fume can be captured and removed safely by a suitable ventilation, exhaust
and filter system and the enclosure provides a guard against mechanical, electrical, thermal and noise risks.
3.2 Function and construction of a spray cabin
3.2.1 General requirements
The spray cabin shall be designed that the noise level outside the cabin fulfils the legal requirements. Even if
more than one piece of equipment is operated the total noise level in the workshop shall fulfil these
requirements.
3.2.2 Features of a spray cabin
There are some different types of spray cabins available.
Usually, modularly built single wall enclosures made out of about 100 mm thick elements are used for plasma,
arc and HVOF spraying processes. They consist of a solid steel sheet on the outer side and a perforate steel
sheet on the side towards the noise source. The space between those sheets is filled with a non-flammable
isolation material, for example with glass wool or rock wool.
Also the doors and windows shall be able to protect the outside working personnel from excessive noise, dust,
gases, fumes and intensive light, IR and UV radiation. Openings needed for electrical cables, gas or water
hoses, and piping for ventilation and exhausting shall be sealed, in order to avoid acoustic tunnelling and to
minimise the escape of dust and vibrations.
If the roof of the spray cabin has to carry installations like ventilator, power sources or heat exchangers and/or
small lifting devices or manipulating equipment have to be mounted onto the ceiling, adequate reinforcement
shall be applied. Sufficient space for maintenance and a safe access to this area is required.
In the case of mechanised spraying, the operator will enter the cabin only for changing the part to be coated or
for maintenance. If loading and unloading of the parts can be executed through an opening, while the spraying
process is shut off, the enclosure can be built as small as possible and thus be more effective for dust
extraction. For automatic processes loading and unloading may be done through a lock, while the process
runs.
3.2.3 Layout for a spray cabin or a thermal spraying equipment in the workshop
Spraying equipment shall not create safety hazards for nearby processes. A spray cabin or the spraying
equipment should be located close to an outside wall to facilitate easy gas supply and the installation and
effectiveness of the ventilation and extraction equipment.
The workshop building should be single storey and be as spacious as possible with a high ceiling and good
natural ventilation achieved by a sufficient number of air inlets, roof vents and opening doors and windows. In
that way, gas accumulation can be avoided in unventilated areas overhead, such as voids above false ceilings
or in voids below floor level, such as pits, service trenches, gullies or underground rooms, where gases
heavier than air could accumulate. A mechanized ventilation can be necessary, in order to draw away gases
heavier than air at lower height, as e. g. LPG, propane, argon.
3.2.4 Ventilation and exhausting for the spray cabin
3.2.4.1 Reasons for ventilation and exhausting
To avoid explosive gas or dust mixtures or hazardous conditions the spray cabin shall be ventilated. A suitable
air change and flow in the spray cabin prevents the formation of a burnable or explosive atmosphere inside
the enclosure, reduces temperature rise, serves for removing gases, fumes, dusts, further by-products and
provides for a safe spraying operation. The filtration of the exhausted air and gas mixture avoids an
inadmissible contamination of the environment. The national or local laws or regulations for emissions into the
atmosphere shall be followed.
3.2.4.2 Ventilation of the spray cabin
The air volume needed for the ventilation of the spray cabin is given by the exhaust air volume. The design of
air inlet into the spray cabin and of the exhausting shall provide an air flow in suitable flow direction and local
speed. A laminar continuous air flow, which can be reached by a great number of small inlet openings equally
distributed is preferred, so far as the air flow is not decisive disturbed by the spraying equipment and the
manipulating system. A turbulent air flow causes swirls and low pressure areas, where dust can remain or fall
out.
The ventilation capacity and speed in the cabin shall function in the sense of displacement ventilation.
Capacity and speed shall serve:
— for an adequate transport of spray dusts to the exhaust system;
— to avoid too low an oxygen content by diluting the atmosphere in the cabin (e. g. in the case of cold
spraying);
— to avoid unacceptable gas concentration, which can remain in dead spots;
— to maintain the air temperature in the duct in a range that the filters will not be damaged (e. g. in the case
of HVOF kerosene spraying).
3.2.4.3 Exhausting the spray cabin
The exhaust volume shall be adequate for the spray process and the size and shape of the exhaust hood and
the component. Table 1 includes typical values in m /h depending on the spray process. It should be noted
that the better the exhaust hood is adjusted to the size and form of the component, the lesser are problems
with remaining dust in the air and on the floor and cabin walls.
The air speed to capture the rebounding particles and those which did not meet the part should be at least
1 m/s in front of the exhaust hood.
In the case of manual spraying in a cabin an Air Change Rate (ACR), see Formula (1) of at least
60 to 180 changes per hour depending on the spraying process is recommended. The Air Change Rate is
calculates as follows:
N = Q/Vol (1)
Where
N number of air changes per hour
Q Volumetric flow rate of air in cubic meter per hour
Vol Space volume: length × width × height, in cubic meter
Table 1 — Exhaust volumes
Spray process Exhaust volume min. m /h
Flame spraying  3 000 to 5 000
Arc spraying 8 000 to 12 000
Plasma spraying 8 000 to 10 000
HVOF (gaseous fuel) 10 000 to 12 000
HVOF (liquid fuel) 12 000 to 15 000
Cold spraying 5 000 to 15 000
Exhaust and ventilation systems will create a lower pressure in the spray cabin. This lower pressure shall not
cause difficulties opening the doors while the extraction is running. An adequate air inlet shall be calculated
and designed to avoid this.
The start of the spray system shall be interlocked with the exhaust system to ensure adequate extraction
during spray operation.
Sometimes ventilators with two running speeds are recommended either to keep a low ventilation level mode,
if the cabin door is opened for maintenance, set-up or teach-in programming or to increase the ventilator
capacity in the case of emergency to avoid a dangerous or explosive atmosphere in the cabin.
The exhaust system should have a short run lengths and preferably should lead only from one or two spray
equipment to each collector. The exhaust and filter system should have smooth walls inside and no dead
spots where dust can accumulate. The exhaust channel should have as few bends as possible of large a
radius as possible to avoid loss of pressure and gathering of dust. The recommended air speed in the duct
should be between 16 m/s and 25 m/s. Accessibility for cleaning and inspection is required.
Depending on the material sprayed, additional measures shall be taken to avoid fire and explosion risks.
Generally, the national or local regulations shall be fulfilled.
3.3 Equipment in the spray cabin
3.3.1 General
Often a spray cabin contains the part fixture system (turning device for spraying, turn table, automatic part
changing equipment, etc.), the manipulator system to move the spray torch (industrial robot, X-Y-Z-axis
manipulator system, etc.), the exhaust hood for spray dust, fume, and heat, exhaust channels, and the spray
torch with its hose assembly, and devices for cooling the part.
The control panel shall be mounted outside the spray cabin for mechanised or automatic spraying, for manual
spraying it can also be mounted outside, if a second person with visual contact to the spraying area is present.
This person shall monitor the process and shut-off the spray system in case of emergency.
Sources of danger identified by a risk assessment shall be considered and marked, if appropriate, for example
by mechanical barriers, stop devices, warning barriers, warning signs.
3.3.2 Function and description of the manipulating systems
Manipulating systems can help to increase the quality assurance and to avoid exposures of the operating
personnel. They can be of:
— linear speed traverse;
— rotating tables;
— X-Y-Z-axis manipulator; or
— industrial robot type.
The safety requirements for industrial robots are specified in EN ISO 10218-2.
3.3.3 Electrical equipment and installation
Electrical Apparatus is a prime source for ignition an explosive atmosphere. The installation shall conform to
the EN ISO 60204-1 and the local national regulations for electrical installations including the electromagnetic
compatibility according to EN 60974-10 and to the manufacturer's instructions.
The safety relevant control loops, determined by the risk assessment, shall be developed according to
EN 13849-1.
3.4 Extraction and filtering equipment
3.4.1 General
Its purpose is to collect, extract and filter the spray dust from the air, in order to remove the fine sized particles
before the air is released to the atmosphere. The limiting values for emission of fine, coarse and carcinogenic
dusts are specified in National Environmental Legislation. Wet extraction is not suitable for thermal spraying
applications, because it is not able to meet emission reduction requirements.
3.4.2 Dry extraction
3.4.2.1 Dry working collector systems
Sprayed particles, which either miss the part or rebound from it, should be captured close to their source of
creation. The extraction equipment can vary from:
— a basic hood behind the part to be coated, adequately adjusted to its shape and the local conditions and
moved correspondingly with the motion of the spray torch; or
— floor extraction system ('floorwash'), which can provide a higher extraction rate of sprayed particles and
better cleanliness in the spray cabin. However, the energy needed to capture and transport the particles
is extremely high;
— other systems which use for example, part of the cabin wall or a combination of several systems.
The air speed shall be a minimum of 1 m/s in front of the hood. A fire trap should be mounted to prevent hot
particles getting into the filter, especially if arc spraying is applied.
3.4.2.2 Dry extraction systems – filter systems
As a pre-filtering operation multi cell cyclones can be used for pre-extraction of coarse grain particles to avoid
over loading or damage of the cartridge filter elements. However, they are not able to capture spray particles
below 5 μm in size.
Usually, cartridge filters, which possess an efficiency of > 99%, are used. They comprise a series of filter
elements folded to form a pleated material, mounted within a steel casing. Due to mounting of the elements in
several rows the required filter surface can be reached and can avoid exceeding the admissible surface
loading. It is recommended that the filter should be located outside the building, so that the safe opening of an
explosion vent is possible.
Filtration method, exhaust air speed, and cleaning of the cartridges depend upon the spraying process and its
running time. Cleaning the cartridges is carried out automatically by periodic reverse pulsing with compressed
air while operating. A suitable cleaning cycle provides a suitable free filter surface at all times.
The maximum operation temperature of the filter cartridge shall be considered. Typically, this value is 60°C.
To avoid an inadmissible emission into the environment in the case of damaged or broken filter elements a
pressure sensor, shall detect any altera
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