Attachment 11-ufc_3_410_04_2017.pdf

UFC 3-410-04

13 December 2017

UNIFIED FACILITIES CRITERIA (UFC)

INDUSTRIAL VENTILATION

APPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED

INDUSTRIAL VENTILATION

Any copyrighted material included in this UFC is identified at its point of use.

Use of the copyrighted material apart from this UFC must have the permission of the copyright holder.

U.S. ARMY CORPS OF ENGINEERS

NAVAL FACILITIES ENGINEERING COMMAND (Preparing Activity)

AIR FORCE CIVIL ENGINEER SUPPORT AGENCY

Record of Changes (changes are indicated by \1\ ... /1/)

Change No. Date Location

This UFC supersedes UFC 3-410-04N, Industrial Ventilation, dated 21 October 2004.

FOREWORD

The Unified Facilities Criteria (UFC) system is prescribed by MIL-STD 3007 and provides planning, design, construction, sustainment, restoration, and modernization criteria, and applies to the Military Departments, the Defense Agencies, and the DoD Field Activities in accordance with USD (AT&L) Memorandum dated 29 May 2002. UFC will be used for all DoD projects and work for other customers where appropriate. All construction outside of the United States is also governed by Status of Forces Agreements (SOFA), Host Nation Funded Construction Agreements (HNFA), and in some instances, Bilateral Infrastructure Agreements (BIA.)

Therefore, the acquisition team must ensure compliance with the most stringent of the UFC, the SOFA, the HNFA, and the BIA, as applicable.

UFC are living documents and will be periodically reviewed, updated, and made available to users as part of the Services’ responsibility for providing technical criteria for military construction. Headquarters, U.S. Army Corps of Engineers (HQUSACE), Naval Facilities Engineering Command (NAVFAC), and Air Force \2\ Civil Engineer Center (AFCEC) /2/ are responsible for administration of the UFC system. Defense agencies should contact the preparing service for document interpretation and improvements. Technical content of UFC is the responsibility of the cognizant DoD working group. Recommended changes with supporting rationale should be sent to the respective service proponent office by the following electronic form: Criteria Change Request. The form is also accessible from the Internet sites listed below.

UFC are effective upon issuance and are distributed only in electronic media from the following source:

• Whole Building Design Guide web site http://dod.wbdg.org/.

Refer to UFC 1-200-01, DoD Building Code (General Building Requirements), for implementation of new issuances on projects.

AUTHORIZED BY:

LARRY D. McCALLISTER, PhD, PE, PMP, SES

JOSEPH E. GOTT, P.E.

Chief Engineer

Chief, Engineering and Construction Directorate of Civil Works

Naval Facilities Engineering Command

U.S. Army Corps of Engineers

EDWIN H. OSHIBA, SES, DAF MICHAEL McANDREW Deputy Director of Civil Engineers DCS/Logistics, Engineering & Force Protection

Deputy Assistant Secretary of Defense (Facilities Investment and Management) Office of the Assistant Secretary of Defense (Energy, Installations, and Environment) http://www.wbdg.org/pdfs/ufc_implementation.pdf http://www.wbdg.org/ccb/browse_cat.php?o=29&c=4 http://dod.wbdg.org/

NEW DOCUMENT SUMMARY SHEET

Document: UFC 3-410-04, Industrial Ventilation, 13 December 2017 Superseding: UFC 3-410-04N, Industrial Ventilation, 21 October 2004

Description: This UFC provides criteria for the design of ventilation systems that control contaminants generated from industrial processes.

Reasons for Document: This is a new Joint Service document. This new document represents another step in the Joint Services effort to bring uniformity to the planning, design and construction of military facilities. This UFC was developed to provide design requirements to accomplish the following:

• Assist designers in understanding the system requirements for ventilation systems.

• Provide architects, engineers, and construction surveillance personnel with the essential, minimum requirements for the design of ventilation systems that control contaminants generated from industrial processes.

• Clarify the operational intent of the system design.

Impact: The following will result from the publication of this UFC:

• This UFC creates a single source for common DoD industrial ventilation system criteria and an accurate reference to individual Service-specific documents.

• This UFC facilitates updates and revisions and promotes agreement and uniformity of design and construction between the Services.

Non-Unification Issues: The following are issues that remain non-unified and the reasoning for each:

• Section 2-1 identifies different safety standards for each Service. These standards are operational in nature and have not been unified.

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TABLE OF CONTENTS

CHAPTER 1 INTRODUCTION

1-1 SCOPE

1-2 PURPOSE OF CRITERIA

1-3 SPECIFIC PROCESSES

CHAPTER 2 GENERAL REQUIREMENTS

2-1 GENERAL CRITERIA

2-2 COORDINATION

2-3 DESIGN PROCEDURE

2-3.1 Step 1

2-3.2 Step 2

2-3.3 Step 3

2-3.4 Step 4

2-3.5 Step 5

2-3.6 Step 6

2-3.7 Step 7

2-3.8 Step 8

2-3.9 Step 9

2-4 2-4 DESIGN CRITERIA

2-4.1 Ductwork

2-4.2 Fans

2-4.3 Exhaust Stacks

2-4.4 Air Pollution Control Equipment

2-4.5 Replacement Air

2-5 CONTROLS

2-5.1 Gauges and Sensors

2-5.2 Interlocks

2-5.3 Annunciator Panel

2-5.4 Security

2-6 OPERATIONAL CONSIDERATIONS

2-6.1 Provision for System Testing

2-6.2 Energy Conservation ii

2-6.3 Recirculation

2-6.4 Maintenance

2-7 SAFETY AND HEALTH CONSIDERATIONS

2-7.1 Posting

2-7.2 Noise

2-7.3 Respiratory Protection

2-7.4 Emergency Showers and Eyewash Stations

2-7.5 Hygiene Facilities

2-8 COMMISSIONING

CHAPTER 3 ASBESTOS DELAGGING FACILITIES

3-1 FUNCTION

3-2 OPERATIONAL CONSIDERATIONS

3-2.1 Airborne Contamination

3-2.2 Heat Stress

3-2.3 Employee Workflow

3-3 TYPICAL FLOOR PLANS

3-4 DESIGN CRITERIA

3-5 EXHAUST AIR

3-5.1 Hood Design

3-5.2 Ductwork

3-5.3 Fans

3-5.4 Weather Stack Design and Location

3-5.5 Air Cleaning Devices

3-5.6 Industrial Vacuum System

3-5.7 Replacement Air

3-5.8 System Controls

3-6 TREATMENT OF WASTE EFFLUENT

3-7 SAFETY AND HEALTH CONSIDERATIONS

CHAPTER 4 OTTO FUEL II FACILITIES

4-1 FUNCTION

4-2 OPERATIONAL CONSIDERATIONS

4-3 DESIGN CRITERIA

4-3.1 Exhaust Air for MK-46 Ventilated Spaces iii

4-3.2 Exhaust Air for MK-48 Ventilated Spaces

4-3.3 Weather Stack Design and Location

4-3.4 Air Cleaning Devices

4-3.5 Replacement Air

4-3.6 Heating and Air Conditioning

4-4 SYSTEM CONTROLS

4-5 SAFETY AND HEALTH CONSIDERATIONS

4-5.1 Emergency Eyewash and Shower Stations

CHAPTER 5 COMPOSITE FABRICATION AND REPAIR FACILITIES

5-1 FUNCTION

5-2 OPERATIONAL CONSIDERATIONS

5-3 FLOOR PLAN

5-4 DESIGN CRITERIA

5-4.1 Exhaust Air System

5-4.2 Hood Design

5-4.3 Ductwork

5-4.4 Fans

5-4.5 Weather Stack Design and Location

5-4.6 Air Cleaning Devices

5-4.7 Industrial Vacuum System

5-5 REPLACEMENT AIR

5-6 SYSTEM CONTROLS

5-7 SAFETY AND HEALTH CONSIDERATIONS

CHAPTER 6 ABRASIVE BLASTING FACILITIES

6-1 FUNCTION

6-2 OPERATIONAL CONSIDERATIONS

6-3 DESIGN CRITERIA

6-3.1 Exhaust Air

6-3.2 Blasting Cabinets

6-3.3 Walk-in Blasting Enclosures

6-3.4 Access Doors and Observation Windows

6-3.5 Air Cleaning Devices

6-3.6 Recirculation iv

6-3.7 Media Reclamation

6-3.8 Ductwork

6-3.9 Fans

6-3.10 Weather Stack Design and Location

6-3.11 Replacement Air Ventilation Systems

6-3.12 Heating and Air Conditioning

6-3.13 System Controls

6-4 SAFETY AND HEALTH CONSIDERATIONS

6-4.1 Respiratory Protection

6-4.2 Air Supply and Air Compressors

6-4.3 Noise

6-4.4 Hygiene Facilities

CHAPTER 7 WOOD SHOP FACILITIES

7-1 FUNCTION

7-2 OPERATIONAL CONSIDERATIONS

7-3 FLOOR PLAN LAYOUT

7-4 DESIGN CRITERIA

7-4.1 Dust Collection System

7-4.2 Hood Design

7-4.3 Floor Sweeps

7-4.4 Ductwork

7-4.5 Blast Gates

7-4.6 Duct Support

7-4.7 Clean Out Panels

7-4.8 Exhaust Fans

7-4.9 Weather Stack Design and Location

7-4.10 Air Cleaning Devices

7-4.11 Building Heating and Air Conditioning

7-5 SAFETY AND HEALTH CONSIDERATIONS

CHAPTER 8 BATTERY MAINTENANCE FACILITIES

8-1 FUNCTION

8-2 OPERATIONAL CONSIDERATIONS

8-3 DESIGN CRITERIA

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8-3.1 Exhaust System

8-3.2 Ductwork

8-3.3 Fans and Motors

8-3.4 Weather Stack Design and Location

8-3.5 Air Cleaning Device

8-3.6 Replacement Air

8-3.7 System Controls

8-4 SAFETY AND HEALTH CONSIDERATIONS

CHAPTER 9 PAINT SPRAY BOOTHS

9-1 FUNCTION

9-2 OPERATIONAL CONSIDERATIONS

9-2.1 Painting Equipment Types

9-3 DESIGN CRITERIA

9-3.1 Walk-in Spray Paint Booths

9-3.2 Storage and Mixing Room

9-3.3 Small Spray Booths and Paint Mix Hoods

9-4 FANS AND MOTORS

9-5 REPLACEMENT AIR

9-5.1 Air Distribution

9-5.2 Heating and Air Conditioning

9-6 SYSTEM CONTROLS

9-7 SAFETY AND HEALTH CONSIDERATIONS

CHAPTER 10 AIRCRAFT CORROSION CONTROL HANGARS . ERROR! BOOKMARK

NOT DEFINED.

10-1 FUNCTION. ................................... ERROR! BOOKMARK NOT DEFINED.

10-2 DESIGN CRITERIA. ...................... ERROR! BOOKMARK NOT DEFINED.

APPENDIX A REFERENCES

APPENDIX B GLOSSARY

B-1 TERMS

B-2 ABBREVIATIONS AND ACRONYMS

FIGURES

FIGURE 2-1. EXHAUST STACK DESIGNS

vi

FIGURE 2-2. DECISION TREE FOR REPLACEMENT AIR DESIGN

FIGURE 2-3. PLENUM DESIGN WITH PERFORATED DUCT

FIGURE 2-4. PLENUM DESIGN WITHOUT PERFORATED DUCT

FIGURE 2-5. ANNUNCIATOR PANEL

FIGURE 3-1. DELAGGING FACILITY FLOOR PLAN

FIGURE 3-2. EXHAUST HOOD FOR HIGH PROFILE WORK PIECES

FIGURE 3-3. EXHAUST HOOD FOR LOW PROFILE WORK PIECES

FIGURE 3-4. SEQUENCE OF AIR CLEANING DEVICES FOR ASBESTOS

DELAGGING

FIGURE 4-1. LAYOUT FOR THE MK-46 FUEL/DEFUEL AND AFTERBODY

BREAKDOWN ROOM

FIGURE 4-2. SERIES OF HOOD IN THE MK-46 SHOP

FIGURE 4-3. MK-46 STANDUP BACKDRAFT HOOD

FIGURE 4-4. MK-46 WORKBENCH HOOD

FIGURE 4-5. MK-46 PARTS WASHER HOOD

FIGURE 4-6. TYPICAL MK-48 VENTILATED SPACE LAYOUT

FIGURE 4-7. MK-48 AFTERBODY TEARDOWN HOOD

FIGURE 4-8. MK-48 WORKBENCH HOOD

FIGURE 4-9. MK-48 PARTS WASHER HOOD

FIGURE 4-10. MK-48 HOOD SEQUENCE AFTERBODY TEARDOWN AND

ACCESSORIES ROOMS

FIGURE 4-11. MK-48 REFUELING HOOD

FIGURE 4-12. VERTICAL DISTRIBUTION METHOD

FIGURE 4-13. HORIZONTAL DISTRIBUTION METHOD

FIGURE 5-1 EXAMPLE FLOOR PLAN FOR A COMPOSITE FACILITY

FIGURE 5-2. WORKBENCH HOOD

FIGURE 5-3. FLOOR EXHAUST

FIGURE 5-4. SPRAY UP BOOTH

FIGURE 5-5. VENTILATED SINK

FIGURE 5-6. EXHAUST SYSTEM SCHEMATIC

FIGURE 6-1. DOWNDRAFT BLAST ENCLOSURE

FIGURE 6-2. CROSSDRAFT BLAST ENCLOSURE

FIGURE 7-1. FLOOR SWEEP

vii

FIGURE 8-1. VENTILATION SYSTEM FOR BATTERY MAINTENANCE FACILITIES.

FIGURE 9-1. WALK-IN DOWNDRAFT PAINT BOOTH

FIGURE 9-2. DRIVE-THROUGH CROSS DRAFT PAINT BOOTH WITH

MECHANICAL REPLACEMENT AIR

FIGURE 9-3 DRIVE-THROUGH CROSSDRAFT PAINT BOOTH WITH NO

MECHANICAL REPLACEMENT AIR

FIGURE 9-4 PAINT MIXING HOOD AND WORK BENCH

TABLES

TABLE 3-1. MINIMUM VOLUMES AND VACUUM HOSE SIZE FOR ASBESTOS

OPERATIONS

TABLE 5-1. RECOMMENDED HOOD, CAPTURE VELOCITY, AND AIR POLLUTION

DEVICE

viii

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CHAPTER 1 INTRODUCTION

1-1 SCOPE.

This Unified Facilities Criteria (UFC) provides criteria for the design of ventilation systems that control contaminants generated from industrial processes.

1-2 PURPOSE OF CRITERIA.

Criteria are developed to define requirements during the design of industrial ventilation systems. Chapter 2 provides general criteria and Chapters 3 through 10 provide criteria for specific processes. Use the general criteria presented in Chapter 2 along with the applicable specific criteria presented in Chapters 3 through 10 to design the ventilation system. For all other ventilation applications, use the criteria in Chapter 2.

Criteria contained in this UFC should be interpreted as the minimum required and should be improved where current technology or situation warrants. Users of this UFC are advised to consult the most current edition of the standards.

This UFC does not incorporate individual state and local environmental requirements. It is the sole responsibility of the cognizant design personnel to design an industrial ventilation system that complies with state and local environmental requirements. It is also the responsibility of the cognizant design personnel to design an industrial ventilation system that is energy efficient.

1-3 SPECIFIC PROCESSES.

The specific processes addressed in this UFC are asbestos delagging, torpedo refurbishing (Otto Fuel II), composites fabrication and repair, abrasive blasting, woodworking, battery maintenance, and paint spray booths. Requirements for aircraft corrosion control facilities are located in UFC 4-211-02, Aircraft Corrosion Control and Paint Facilities.

1-4 APPLICABILITY.

This UFC is applicable to all service elements and contractors involved in the planning, design and construction of DoD facilities worldwide. Where conflicts in requirements appear between sections of any mechanical UFC or applicable codes or laws, the most restrictive requirement will govern.

1-5 GENERAL BUILDING REQUIREMENTS.

Comply with UFC 1-200-01, DoD Building Code (General Building Requirements). UFC 1-200-01 provides applicability of model building codes and government unique criteria for typical design disciplines and building systems, as well as for accessibility, antiterrorism, security, high performance and sustainability requirements, and safety.

Use this UFC in addition to UFC 1-200-01 and the UFCs and government criteria referenced therein.

1-6 CYBERSECURITY.

All control systems (including systems separate from an energy management control system) must be planned, designed, acquired, executed, and maintained in accordance with DoD Instruction 8500.01, DoD Instruction 8510.01, and as required by individual Service Implementation Policy

CHAPTER 2 GENERAL REQUIREMENTS

2-1 GENERAL CRITERIA.

Installing engineering controls is the preferred method of controlling hazardous processes as specified in 29 CFR 1910.1000(e), Air Contaminants and OPNAVINST 5100.23, Navy Occupational Safety and Health Program Manual, AFOSHSTD 91-501 Air Force Consolidated Occupational Safety standard, and EM 385-1-1 USACE Safety and Health Requirements Manual. Properly designed industrial ventilation systems are the most common form of engineering controls.

2-2 COORDINATION.

Form a project design team to direct the design of industrial ventilation projects. Include in the design team representatives from:

• Affected industrial shop.

• Public Works or Base Civil Engineer.

• Health and Safety Office.

• Cognizant Regional Engineering Office (REO) (for example: Navy Facility Engineering Command, Army Corps of Engineers District, and Air Force major command engineering office). The REO representative establishes a design team and acts as the team leader in all cases, except when the cognizant REO grants a variance.

• Industrial Hygiene (IH) Offices.

NOTE U.S. NAVY: BUMED or activity IH. Use Navy and Marine Corps Public Health Center as a back-up.

• Systems or major command program manager (where applicable).

• System safety engineer.

• Environmental manager.

2-3 DESIGN PROCEDURE.

Refer to the ACGIH, Industrial Ventilation; A Manual of Recommended Practice for Design (IV Design Manual), Chapter 9, “Local Exhaust Ventilation System Design Calculation Procedures” for system design calculations. In addition, design all industrial ventilation systems in accordance with Steps 1-9 in the paragraphs below.

2-3.1 Step 1.

Identify all significant contaminant sources that require ventilation control. Request the local industrial hygiene office to provide a source characterization with area diagrams of the contaminant sources, and employee work areas. Also, consider how the system being designed might affect the performance of any existing processes, industrial ventilation systems or HVAC systems.

2-3.2 Step 2.

Coordinate with permitting agencies to determine specific permitting requirements. Also determine documentation and system monitoring requirements.

2-3.3 Step 3.

Consider how the facility is to be used or expanded in the future. It may be possible to initially specify fans that are capable of handling future needs at minimal increased cost.

2-3.4 Step 4.

Select or design the exhaust hood that best suits the work piece or operation. Design the exhaust hood to enclose the work piece or operation as much as possible. This will reduce the ventilation rates required to provide contaminant control. This UFC provides optimum exhaust hood designs for many of the operations covered.

2-3.5 Step 5.

Determine the capture velocity required to control generated contaminants. Capture velocities in this UFC are specified assuming there are no cross drafts or turbulence that adversely affects the capture efficiency. Reduce potential for cross drafts or turbulence near a given exhaust hood by properly locating and designing the hood with baffles, and also by designing the replacement air system to complement the exhaust system. Pay close attention to how air diffuses into the room near the local exhaust ventilation system.

2-3.6 Step 6.

Determine the exhaust volumetric flow, in cubic feet per minute (cfm) [cubic meters per second (m3/s)], required to maintain the capture velocity determined in previous step.

2-3.7 Step 7.

Create a line drawing of the proposed system. Include plan and elevation dimensions, fan location and air cleaning device location. Identify each hood, branch duct and main duct sections.

2-3.8 Step 8.

Size ductwork using the balance by design or the blast gate method. Maintain the required minimum transport velocity throughout the system.

2-3.9 Step 9.

Determine requirements for replacement air. Based on the process, determine if the room must be slightly negative or neutral pressure with respect to the surrounding area.

The surrounding area can be either outside the building envelope or an adjacent room or hallway. Determine if tempered replacement air is needed.

2-4 DESIGN CRITERIA.

Several design criteria are common to all industrial ventilation systems; use the ACGIH IV Design Manual and this document for primary guidance. If conflicts exist, this UFC takes precedence. See the following paragraphs in Chapter 2 for general requirements, plus Chapters 3 through 9 for design requirements on specific types of facilities.

Incorporate the guidelines provided in UFC 1-200-02, High Performance and Sustainable Building Requirements, for system design and equipment selection.

2-4.1 Ductwork.

In addition to the recommendations of the ACGIH IV Design Manual and requirements of NFPA 91 section on Duct Materials and Construction, consider the following when designing a ventilation system.

a. Specify duct gage, reinforcement schedule and hanger design and spacing, in accordance with SMACNA RIDCS, Round Industrial Duct Construction Standards for round duct and SMACNA RTIDCS, Rectangular Duct Construction Standards for rectangular duct.

b. Install clean-out doors in ductwork that conveys particulate material such as wood dust or blasting grit. Mount clean-out doors on top half of horizontal runs near elbows, junctions, and vertical runs.

2-4.2 Fans.

2-4.2.1 Selection.

Except where specified below, fan selection criteria for replacement air fans and exhaust air fans are identical.

a. Select exhaust system industrial fans that meet design pressure and volume flow rate requirements and have the AMCA-certified performance seal. The design pressure requirement must account for any system effects caused by non-uniform airflow into or out of the fan. See AMCA 201, Fans and Systems for more information on system effects. Specify a fan class that is appropriate for the design operating point. Do not select fans with forward curved blades for exhaust or recirculating replacement air-systems.

b. When selecting fan capacity, consider if the process room pressure will be positive, negative or neutral with respect to the external areas. Select a fan that will provide the necessary volumetric flow rate to maintain the desired process room pressure. Ensure that all sources of exhaust air are considered when selecting fan capacity. See the paragraph in Chapter 2 entitled, “Replacement Air” for more details.

c. Specify fan shafts that have a uniform diameter along the entire length.

Use bearings that are rated with an average life of 200,000 hours.

d. Select only energy efficient motors. If available, select “NEMA Premium Efficiency “motors per NEMA MG-1 for motors and generators. Select the motor to handle cold startup amperage for nonstandard air processes.

e. Specify vibration-isolating couplings at the fan inlet and outlet. Mount all fans on vibration isolating bases.

f. If the planner's forecasts change in the processes to occur within the next couple of years, which would require an increase in the amount of replacement or exhaust air, then consider purchasing a larger capacity fan and oversized wiring.

g. Additional fan specification data such as spark resistant construction, drive arrangement, etc. is available in ANSI/AMCA Standards 99-10, “Standards Handbook”.

2-4.2.2 Location.

Locate the exhaust fan after the air pollution control equipment to protect fan blades from contaminated air-stream. Provide access for maintenance to all fans, including ladders and guardrails where necessary. Refer to NFPA 70, National Electrical Code for motor controller and disconnect location requirements. In all cases, install exhaust fans outside the building that they serve. Installing the fan outside the building envelope will isolate the working space from contaminants during fan maintenance, minimize noise inside the building, and ensure that ductwork within the building envelope is under negative pressure.

2-4.3 Exhaust Stacks.

2-4.3.1 Design Considerations.

Refer to the ACGIH IV Design Manual for exhaust stack design criteria. The best designs are cylindrical, vertical discharge stacks as shown in Figure 2-1. The best protection from rain, when the ventilation system is not running, is the “offset stack” design C, as shown in Figure 2-1. Water may still enter the system with straight stack design A. Provide a means to drain water from the fan housing.

Figure 2-1. Exhaust Stack Designs.

2-4.3.2 Location and Structural Considerations.

Refer to ASHRAE Handbook, Fundamentals for information on airflow around buildings.

Do not select stack locations based exclusively on prevailing winds. A stack must provide effluent dispersion under all wind conditions. Refer to UFC 1-200-01, General Building Requirements for exhaust stack structural design considerations. Some structural considerations are wind load, lightning protection, and stack support. Refer to SMACNA GSSDC, Guide for Steel Stack Design and Construction for additional information.

2-4.4 Air Pollution Control Equipment.

Requirements for air pollution equipment vary by process and geographical region in the United States. Contact the local activity environmental manager to determine the pollution control requirements for the process.

2-4.5 Replacement Air.

Replacement air is as important as exhaust air in controlling industrial process contaminants. The quantity and, in particular, the distribution of the replacement air profoundly affects the exhaust hood performance. Properly designed replacement air will (1) ensure that exhaust hoods have enough air to operate properly, (2) help to eliminate cross-drafts through window and doors, (3) ensure proper operation of natural draft stacks, (4) eliminate cold drafts on workers, and (5) eliminate excessive differential pressure on doors and adjoining spaces. (6) Ensure that replacement air does not draw from a loading dock or parking lot area or where exhaust air could be drawn into the system. Design the replacement air system in accordance with the decision tree shown in Figure 2-2.

Figure 2-2. Decision Tree For Replacement Air Design.

2-4.5.1 Space Pressure Modulation.

Modulate the replacement air to maintain the required space pressure differential between the process area and adjacent spaces, while maintaining the exhaust flow.

Operate all process areas and/or buildings at a slight negative pressure to prevent the controlled contaminant from migrating into clean areas and prevent fugitive emissions to the atmosphere. Use a variable frequency drive (VFD) motor to control the fan speed.

Do not use barometric dampers or sensor controlled transfer grilles to control replacement air quantity.

Exhaust hoods require a specific amount of exhaust air to control the contaminant.

Certain conditions (e.g., paint curing or unattended lab hood processes) may permit an exhaust flow reduction. Worker protection takes precedence over energy savings.

2-4.5.2 Plenum Design.

The replacement air configuration which provides the most operational flexibility and worker protection is a down flow design, with the replacement air being delivered from the ceiling. The following discussion is based primarily on a down flow system, although a cross flow system may be utilized if the down flow arrangement proves to be impractical. Consider worker breathing zone when designing and balance the energy usage with worker protection.

Use perforated plate to cover as much of the ceiling (or wall opposite the exhaust hood(s)) as practical. The diameter of the perforation should be between 1/4 in and 3/8 in (6.3 mm and 9.5 mm). Perforated plenums work best when ceiling height is less than 15 ft (4.58 m). Use either of the following two choices for replacement air plenum design:

a. Design for 1,000 fpm (5.1 m/s) replacement air velocity through the open area of the perforated plate if perforated duct is used inside the plenum as shown in Figure 2-3.

b. Design for 2,000 fpm (10.2 m/s) replacement air velocity through the open area of the perforated plate if the plenum is served with ducts using diffusers, grills or registers as shown in Figure 2-4.

Figure 2-3. Plenum Design With Perforated Duct.

Figure 2-4. Plenum Design Without Perforated Duct.

2-4.5.3 Perforated Duct Design.

Use perforated duct to evenly distribute the flow of replacement air inside a plenum or use alone when ceiling height is greater than 15 ft (4.58 m). Manufacturers provide several different types and sizes of perforated duct. Use recommendations from the manufacturer for duct design. The manufacturer will not only recommend the size, shape, and type of the required perforated duct, but also the location of the orifices and reducers to distribute the air properly.

2-5 CONTROLS.

Provide industrial ventilation system controls and associated alarms to ensure contaminant control, space specific balance and conditioning, a safe and healthy work environment, and system malfunction notification.

Comply with Standard 18, Emergency Air Distribution Shutoff, found in UFC 4-010-01, DoD Minimum Antiterrorism Standards for Buildings. A hazardous exhaust system may continue to operate if de-energizing the system will violate building codes, fire codes, create an unsafe condition or imperils life safety.

2-5.1 Gauges and Sensors.

Specify gauges and sensors to provide continuous monitoring of system performance.

The minimum requirements are:

2-5.1.1 Differential Pressure Sensors

Provide differential pressure sensors, with gauge readouts, across each replacement air filter section and the exhaust air cleaning sections. Program control system alarm set points for each filter differential sensor to indicate when the filter pressure drop falls below the initial “clean” filter differential pressure or rises beyond the final “dirty” filter differential pressure. Provide text and graphical representation for the low pressure alarm and the high pressure alarm indications.

2-5.1.2 Replace Fan Motor Sensors

Operating light on replacement air system fan motor.

2-5.1.3 Static Pressure Sensors

Static pressure sensor at the outlet of the replacement air fan with a gauge readout.

Alarms must be triggered when the pressure is lower than the recommended range (as determined by baseline testing).

2-5.1.4 Hood Static Pressure Sensors

Hood static pressure sensor, for critical processes or process where extremely toxic substances are used, with a gauge mounted in a conspicuous place near the hood. An alarm must be triggered when the static pressure is lower or higher than the recommended range (as determined by baseline testing). Do not use the type of inline flow sensor, which measures the pressure drop across an orifice plate. Use only a static pressure tap and differential pressure gauge.

2-5.1.5 Fan Static Pressure Sensors

Static pressure sensor at the exhaust fan inlet with gauge readout. An alarm must be triggered when the pressure is lower than the recommended range (as determined by baseline testing).

2-5.1.6 Exhaust Air Motor Sensor

Operating light on exhaust air system motor. When a sensor indicates a malfunction, trigger an alarm that is both audible and visible in the shop space.

2-5.1.7 Gauge Operating Range

Operating ranges on all gauges clearly marked. Locate gauges on an annunciator panel (except hood static pressure gauges). Provide a 3-way valve at each gauge connection for cleanout and calibration; see Figure 2-5.

2-5.1.8 Differential Pressure Sensor Location

Place room differential pressure sensors away from doors, windows, and replacement air discharge.

2-5.2 Interlocks.

Provide an interlocked on-off switch so that the replacement air and exhaust air systems operate simultaneously. When there are multiple fans, clearly label which exhaust fan is interlocked with which supply fan.

2-5.3 Annunciator Panel.

Provide an annunciator panel to allow for continuous monitoring of ventilation system performance. Locate the panel so it is accessible to shop personnel. The panel must include, but is not limited to, all gauges (except hood static pressure gauges) described in the paragraph in Chapter 2, entitled, “Gauges and Sensors”. Mount fan motor operating lights and interlocked ON/OFF switch on the panel. The interlocked switches must clearly show which exhaust and supply fans are interlocked, where multiple fans are used. The panel must indicate what action to take when operation falls outside the prescribed ranges. For example, “examine/replace filter on R.A. unit when this gauge reads outside indicated range.” Connect sensor outputs to building DDC systems when available.

2-5.4 Security.

Any networked communications from controls must meet the Information Assurance security requirements of the Activity served.

Figure 2-5. Annunciator Panel.

2-6 OPERATIONAL CONSIDERATIONS.

2-6.1 Provision for System Testing.

Provide access to the fan and motor to measure voltage, amperage, and fan speed.

Evaluate and incorporate the use of guard rails, working platforms, and OSHA ladders into the design where equipment is located at elevation. Specify that all testing will be done in accordance with the ACGIH Industrial Ventilation, A Manual of Recommended Practice for Operation and Maintenance (IV O&M) Manual, Chapter 3, “Testing and Measurement of Ventilation Systems.”

2-6.2 Energy Conservation.

Incorporate applicable energy conservation measures in the design of all industrial ventilation systems. Criteria herein minimize volume flow rates through appropriate designs. Evaluate life cycle costs for heat recovery systems and specify when appropriate. For HVAC-related issues use UFC 3-410-01, Heating, Ventilation, and Air Conditioning Systems.

2-6.3 Recirculation.

Industrial ventilation systems use a large quantity of air. Exhaust air recirculation is discouraged for most industrial processes and prohibited by OPNAVINST 5100.23, Navy Occupational Safety and Health Program Manual for processes generating lead and asbestos. Follow the re-circulated air guidelines set forth in NFPA 654, Standard for the Prevention of Fire and Dust Explosions from the Manufacturing, Processing, and Handling of Combustible Particulate Solids for fire protection; the ACGIH IV Design Manual, Section 10.8, and ANSI AIHA/ASSE Z9.7, Recirculation of Air from Industrial Process Exhaust Systems for health protection, and the applicable OSHA standards when recirculation is included in the design.

2-6.4 Maintenance.

Require the contractor provide an operation and maintenance manual for the system and also provide hands-on training for maintenance and shop personnel. Ensure safe and sufficient maintenance access to the system components.

2-7 SAFETY AND HEALTH CONSIDERATIONS.

2-7.1 Posting.

For those systems where the replacement air is critical to the proper operation of the system, consider posting the following sign at each entrance to the ventilated space:

KEEP DOOR CLOSED

THIS DOOR MUST BE CLOSED FOR

EFFECTIVE CONTROL OF CONTAMINANTS

2-7.2 Noise.

Use engineering controls as the primary means of protecting personnel from hazardous noise. It is cheaper to eliminate potential noise problems during the design or procurement stages, than it is to retrofit or modify after installation. Determine the acoustic environment in advance, both to fulfill the design goals and prevent the need for corrections at a later stage.

2-7.2.1 Criteria.

Determine the sound power levels for each piece of equipment used for industrial ventilation. Use this information to predict the acoustic characteristics and the resulting ambient noise level. Refer to UFC 3-101-01, Architecture.

Also refer to the appropriate facility-type UFC’s for sound transmission requirements (STC’s) into adjacent building spaces.

For additional information on noise control refer to UFC 3-450-01, Noise and Vibration Control; and OSHA 3048, Noise Control, A Guide for Workers and Employees.

2-7.3 Respiratory Protection.

29 CFR 1910.134(d), Respiratory Protection specifies requirements for respiratory protection. Consult with an industrial hygienist (IH) or occupational health specialist to determine the appropriate type of respiratory protection required for each process.

2-7.3.1 Breathing Air.

Breathing air for supplied air respirators must meet grade D standards as required by 29 CFR 1910.134(d) and defined in Compressed Gas Association Specification for Air G-

7.1. Make up air for the breathing air compressor must be from outside and upwind of any potential exhaust sources. Breathing air couplings must not be compatible with outlets for non-respirable worksite air or other gas systems. Consider providing multiple connection ports for airline respirator hoses to allow worker mobility. Provide a means to permit the IH to test air quality on a routine basis.

2-7.3.2 Air Compressors.

Breathing air systems require a high temperature, carbon monoxide and Oxygen alarm.

Alarms must be located where the respirator user and helper can see and hear them.

Compressors must have the carbon monoxide level monitored to ensure the air supplied contains below 10 ppm CO. Compressors used to supply breathing air must be constructed and situated with a 30 foot separation from sources of contamination (e.g., exhausts, plumbing vents, loading docks) to prevent entry of contaminated air into the air supply system. The breathing air compressor must minimize moisture content so that the dew point is 10 degrees F (5.56 degrees C) below the ambient temperature.

The breathing air system must have suitable in-line air-purifying sorbent beds and filters. Sorbent beds and filter must be maintained per manufacturer’s instructions.

2-7.4 Emergency Showers and Eyewash Stations.

Provide in accordance with UFC 3-420-01, Plumbing Systems, Appendix D.

2-7.5 Hygiene Facilities.

These facilities are adjacent to or nearby the operation when employees are exposed to certain stressors such as asbestos, cadmium, lead, etc. The facilities may be as simple as a hand washing station or as complicated as multiple clean/dirty rooms in an asbestos delagging shop or a facility using metals such as cadmium, lead or hexavalent chromium. Consult with the local industrial hygiene department to determine the extent of and location for these facilities.

2-8 COMMISSIONING.

This process begins before the conceptual design is complete. It is a strategy that documents the occupants’ needs, verifies progress and contract compliance and continues throughout the design, build and acceptance process. DOD projects and construction offices have long used parts of the commissioning process for military construction (MILCON) and some smaller projects. To ensure that issues specific to ventilation are not overlooked, use ASHRAE Guideline 1.1, HVAC &R Technical Requirements for the Commissioning Process.

CHAPTER 3 ASBESTOS DELAGGING FACILITIES

3-1 FUNCTION.

An asbestos delagging facility provides a complete workshop to remove asbestos material from piping, mechanical and structural equipment during ship repair and demolition. The ventilation system design discussed in this section is for activities with extensive asbestos removal operations. The design includes: shop and equipment space, clean and dirty locker rooms for men and women, and administrative space to support the coordination and monitoring of facility operation.

3-2 OPERATIONAL CONSIDERATIONS.

3-2.1 Airborne Contamination.

When asbestos material is removed, the asbestos fibers are dispersed into the air, creating a health hazard. 29 CFR 1910.1001, Asbestos, General Industry and 29 CFR 1915.1001, Asbestos, Shipyards dictate protective measures for workers in these facilities, including respiratory protection and impermeable outerwear. The regulations also prescribe wetting the asbestos material with amended water (water containing a surfactant), if practicable, to reduce the potential for asbestos fibers to become airborne.

3-2.2 Heat Stress.

The physical nature of the work and impermeable outer garments worn by the workers creates heat stress conditions. Provide supplied air respirators with vortex tubes as specified in EPA-560-OPTS-86-001, A Guide to Respiratory Protection for the Asbestos Abatement Industry. Consider cooling the replacement air when supplied air respirators are not available. Consider using "micro climate cooling" or "cool suits," mechanically cooled garments, for individual workers.

3-2.3 Employee Workflow.

Workers enter the clean locker rooms through the control point area. They put on protective outerwear and proceed to the work area. After performing asbestos work, workers remove the outer set of disposable booties as they step in to the decon area.

In the Decon room, the workers will vacuum their protective outerwear and dispose of them in containers provided. They enter the dirty locker rooms and remove the remainder of their work garments. Workers then proceed to the clean locker rooms via the showers, which act as a barrier to the migration of asbestos fibers.

In the shower, the worker can remove and wash their respirator and proceed to the clean room to get dressed in their personal clothing and exit to the control point.

3-3 TYPICAL FLOOR PLANS.

Design floor plans to meet the requirements of 29 CFR 1910.1001 and 29 CFR

1915.1001 and the paragraph in Chapter 3 entitled, “Employee Workflow”. Figure 3-1 shows a sample delagging facility floor plan.

Figure 3-1. Delagging Facility Floor Plan.

3-4 DESIGN CRITERIA.

Design the facility using general technical requirements in Chapter 2 of this UFC and the specific requirements in this Chapter.

3-5 EXHAUST AIR.

Design the exhaust air system to generate 4 exchanges of air/hour and .02 inches (0.5

mm) of water column.

3-5.1 Hood Design.

Design asbestos delagging hood to enclose the work piece as much as possible. Do not use small portable hoods with flexible ductwork because they do not provide consistent capture.

3-5.1.1 Typical Hood Design for High Profile Work Pieces.

Figure 3-2 shows a hood design consisting of a workbench with a central, circular area.

Mount the circular area on sealed bearings to allow easy turning of heavy work pieces.

This design is best for high profile work pieces (for example, boilers, pumps). The hood captures contaminants through the slots into an exhaust plenum. Design each hood with:

a. Two cleanout doors on the front and two doors on the sides of the hood for easy access to asbestos debris. Provide two small cutouts in the outer corners of the workbench to place large pieces of lagging in double bagged containment.

b. The top baffle swings up to allow access to overhead cranes.

Figure 3-2. Exhaust Hood For High Profile Work Pieces.

3-5.1.2 Typical Hood Design for Low Profile Work pieces.

Figure 3-3 shows a hood design consisting of a workbench with a grating strong enough to support the heaviest expected work piece. This is a downdraft hood that draws small pieces of lagging through the grating. The perforated plate below the grating creates even airflow over the grating. This design is best for low profile work pieces such as piping. Design each hood with stands and swinging baffles on each end to accommodate long work pieces (e.g., pipes).

3-5.2 Ductwork.

Size the exhaust ductwork to provide a minimum transport velocity of 5,000 fpm (25.4 m/s). The high velocity is necessary because the practice of wetting the fibers makes them heavier and more difficult to transport. See the paragraph in Chapter 2 entitled, “Ductwork” for general duct considerations.

Figure 3-3. Exhaust Hood For Low Profile Work Pieces.

3-5.3 Fans.

See the paragraph in Chapter 2 entitled, “Fans” for general fan considerations.

3-5.4 Weather Stack Design and Location.

See the paragraph in Chapter 2 entitled, “Exhaust Stacks”.

3-5.5 Air Cleaning Devices.

A delagging facility requires multistage filtering, which consists of a fabric filter collector, prefilters, a mist eliminator, and high efficiency particulate air (HEPA) filters. Prefilters extend the life of the HEPA filters. Use "bag in, bag out" styles of HEPA filters, which allow for safe replacement of the filter element without exposure to asbestos. A mist eliminator before the HEPA filter protects it from the moisture generated during asbestos removal.

a. Have all collectors deliver the collected asbestos to a common pickup point to minimize the risk of exposure. Provide a double acting valve at each collector hopper throat, in accordance with the ACGIH IV Design Manual, Chapter 8, Air Cleaning Devices.

b. Use a single chamber, shaker type collector to minimize the number of collection points.

3-5.5.1 Filter Efficiency.

The fabric filter collector requires a minimum efficiency reporting value (MERV) of not less than 15 in accordance with ASHRAE 52.2, Method of Testing General Ventilation Air Cleaning Devices for Removal Efficiency by Particle Size.

3-5.5.2 Sequencing.

Figure 3-4 illustrates the required sequence of air cleaning devices.

Figure 3-4. Sequence Of Air Cleaning Devices For Asbestos Delagging.

3-5.6 Industrial Vacuum System.

Provide a low volume, high velocity (LVHV) central vacuum system at delagging shops to exhaust fibers and dust from power tools (e.g., grinders and saws) when they are used, as specified in 29 CFR 1910.1001.

3-5.6.1 Central Vacuum System

Design a central vacuum cleaning system, which consists of a motor driven exhauster interconnected with bag type separators.

3-5.6.2 Ductwork

Connect the separator to rigid hose or duct, which extends throughout the plant.

Terminate the rigid hose or duct with inlet valves at the various workstations. Provide flexible hose connections to allow workers to do shop cleanup and to decontaminate their protective outerwear.

3-5.6.3 Exhaust Tools and Hoods

Use local exhaust hoods and high velocity exhaust takeoffs for each hand tool. Table 3- 1 of this UFC and the ACGIH IV Design Manual provide examples of tools and exhaust system for specific operations.

3-5.6.4 Contaminant Capture Distance

Ensure proper capture velocity is produced at each local exhaust hood. Design vacuum systems to reach within 1/2 inch (12.7 mm) of the contaminant source.

3-5.6.5 Pick-up Velocity

Design the pickup air-stream to have a velocity of two to three times the generation velocity for particle sizes from 20 to 30 micrometers (20 to 30 micron.) Design for an additional velocity of: (1) four to five times the generation velocity to pull the particles up through 300 U.S. standard mesh, or (2) six to eight times the generation velocity to pull the particles up through a 20 U.S. standard mesh.

Table 3-1. Minimum Volumes And Vacuum Hose Size For Asbestos Operations.

Hand Tool

Flow rate cfm (m3/s)

Hose Size

in. (mm)

Pneumatic chisel Hand wire brush, 3 x 7 inches Rip out knife Rip out cast cutter Saber saw Saw abrasive, 3 inch General vacuum

125 (0.06) 125 (0.06) 175 (0.08) 150 (0.07) 150 (0.07) 150 (0.07) 200 (0.09)

1.5 (38)

1.5 (38)

1.5 (38)

1.5 (38)

2.0 (51)

Adapted from: Hoffman Air and Filtration Systems, “Design of Industrial Vacuum Cleaning Systems and High Velocity, Low Volume Dust Control.”

3-5.6.6 Air to Asbestos Ratio

Design the air volume for no less than two parts of air to one part of asbestos to be captured by weight.

3-5.6.7 Hose Lengths and Locations

Design the vacuum hose length less than 25 ft (7.6 m). Locate inlet valves 30 to 35 feet (9 to 10.7 meters) apart when a 25 ft (7.6 m) length of hose is used. Locate tool vacuum hose connection on the ends of the workbench underneath the stands. Size the hose based on: (1) air volume per hose, (2) number of hoses to be used simultaneously, and (3) air velocity required to convey the material to the separators.

3-5.6.8 PVC Hoses

Use single-ply, lightweight thermoplastic or polyvinyl chloride (PVC) flexible hose, but limit the usage whenever possible.

3-5.6.9 Multi-stage Blower

Use a multistage centrifugal blower for the vacuum system. Size the blower for: (1) total system pressure loss associated with the total number of hoses to be used simultaneously, and (2) maximum exhaust flow rate entering the inlet of the blower.

3-5.6.10 Blower to Bag House Relationship

Feed the blower directly into the bag house used by the industrial exhaust system to minimize the number of asbestos collection points.

3-5.6.11 Filters and Location

Install a prefilter and a HEPA filter in front of the blower to prevent it from becoming contaminated.

3-5.6.12 Balance by Design

Design the vacuum system duct to balance with the exhaust system duct where the two systems connect.

3-5.6.13 Noise

Use manufacturer guidance to design vacuum system and UFC 3-450-01, Noise and Vibration Control as preliminary guidance.

3-5.7 Replacement Air.

Design replacement air systems with fan inlet guide vanes, variable speed motors, or "eddy current clutch" units to maintain a pressure (relative to the atmosphere) ranging from -0.02 to -0.05 inches wg (12.4 to 24.9 Pa scale) in the shop spaces.

a. Maintain the pressure in decontamination areas, the equipment room, and dirty locker rooms within a range of -0.01 to -0.04 inches wg (-2.49 to -

9.96 Pa). Maintain the pressure in clean spaces within a range of (+0.02 to +0.05 inches wg (+4.98 to +12.4 Pa).

b. For further replacement air system criteria, see the paragraph in Chapter 2, entitled, “Replacement Air”.

3-5.8 System Controls.

Design system controls in accordance with the paragraph in Chapter 2 entitled, “Controls” and the following:

a. Position the annunciator panel at the entrance to the dirty space so operators can monitor operating gauges.

b. Install static pressure sensors at locations that are representative of average static pressure in each controlled space. This will ensure that desired differential pressures are maintained.

c. Trigger a timer if pressure varies from the specified range. Select timer that automatically resets if the problem is corrected within 60 seconds.

d. Trigger both visible and audible alarms if the system cannot correct the difficulty within allotted time. Install multiple alarm beacons if operator's view is obscured during delagging. Monitor the shop's negative pressure continuously, using strip chart recorder, so the operator can detect any pressure changes.

e. Interlock the hand tool power supply with the ventilation system's on-off switch. This will prevent the use of hand tools without ventilation controls.

3-6 TREATMENT OF WASTE EFFLUENT.

All waste water generated in the facility must be considered contaminated effluent and must be filtered to remove solid particulate contaminants prior to entry into the Industrial Waste stream.

Notify and comply with any pretreatment requirements as required by the POTW, state and local authorities prior to discharging any waste water from the facility.

3-7 SAFETY AND HEALTH CONSIDERATIONS.

Consult the local industrial hygienists (IH) for required respiratory protection in accordance with 29 CFR 1910.1001 (f) and (g), 29 CFR 1915.1001(g) and (h). See the paragraph in Chapter 2 entitled, “Respiratory Protection” for additional information.

CHAPTER 4 OTTO FUEL II FACILITIES

4-1 FUNCTION.

MK-46 and MK-48 torpedo facilities maintain, prepare, and test torpedoes. MK-46 and MK-48 torpedoes use Otto Fuel II, a toxic monopropellant. Further best practices and reference documents can be found in the inactive UFC 4-216-02, Design: Maintenance Facilities for Ammunition, Explosives, and Toxins.

4-2 OPERATIONAL CONSIDERATIONS.

Operations in a torpedo facilities create a potential for personnel exposure to one or more of the following: (1) Otto Fuel II, (2) Agitene - parts cleaning solvent used in MK-46 shops, (3) hydrogen cyanide - a product of combustion in torpedoes, and (4) mineral spirits - parts cleaning agent used in MK-48 shops.

4-3 DESIGN CRITERIA.

Design the facilities using general technical requirements in Chapter 2 of this UFC and the specific requirements in this Chapter. Torpedo size differences and maintenance procedures dictate the use of different floor plans and exhaust hood designs for the two types of facilities. Refer to NAVSEA OP5, Volume 1, Ammunition and Explosives Ashore Safety Regulations for Handling, Storing, Production, Renovation and Shipping for the specific order of operations. In all cases, the industrial ventilation systems must remove hazardous vapor (from Otto Fuel II, and part cleaning solvent) and products of combustion.

4-3.1 Exhaust Air for MK-46 Ventilated Spaces.

The MK-46 floor plan in Figure 4-1 optimizes the workflow while allowing the ventilation system to control airborne contaminants. Figure 4-2 shows an elevation view of this floor plan.

Figure 4-1. Layout for the MK-46 Fuel/Defuel and Afterbody Breakdown Room.

Figure 4-2. Series of Hood in the MK-46 Shop.

4-3.1.1 MK-46 Standup Backdraft Hood.

Workers uncouple the fuel section and the engine section of the torpedo in teardown operations. During these operations, Otto Fuel II remains in the lines, in the components of the engine section, and in the fuel tank. The residual fuel releases vapor into the air. The defueling and refueling processes also release Otto Fuel II vapor.