Why LEV Matters_ The Missing Link in Flashback Arrestor Testing and Welding Safety

1. Why LEV Matters: The Missing Link in Flashback Arrestor Testing and Welding Safety It was just another day on the job—until it wasn’t. In 2024, a Queensland welder was killed instantly when an empty fuel drum exploded beneath him. Despite appearing safe, residual vapours inside the drum ignited during a routine welding task. The incident shocked the industry and made national headlines. Investigators pointed to a lack of proper ventilation and risk assessment as contributing factors. It was a grim reminder that in welding, invisible hazards—like trapped fumes or gas build-up—can turn deadly in seconds. This tragedy puts a spotlight on a critical safety gap: too many workshops still rely on general ventilation and miss the life-saving potential of local exhaust ventilation (LEV). In this article, we unpack what LEV systems actually do, how they differ from basic fans, and why they must be part of your fume control strategy—especially in environments where flashback arrestor testing is already part of your safety routine.

2. Why Local Exhaust Ventilation Matters More Than You Think Welding fumes don’t just vanish into thin air. In enclosed or semi-enclosed bays, airborne particles and toxic gases can quickly concentrate—especially when welding materials like stainless steel, aluminium, or galvanised steel. Without task-specific fume extraction, workers are left vulnerable to long-term respiratory illness, metal fume fever, or worse. General Ventilation vs Local Exhaust Ventilation System Type Purpose Drawback General Ventilation Circulates air in a room Doesn’t capture fumes at the source LEV System Captures and removes fumes directly at weld point Requires design and maintenance investment How LEV Systems Actually Work

3. A local exhaust ventilation system is made up of the following components: ● Hood/Extraction Arm: Placed close to the fume source (e.g., MIG gun, weld seam) ● Ducting System: Carries contaminated air away from the operator ● Filter Unit: Removes toxic particles and gases from the airflow ● Fan or Blower: Drives airflow through the system When correctly installed and used, LEV dramatically reduces exposure to hazardous airborne contaminants. Key Installation Tips for Welding Bays Every welding station needs a setup that reflects both its work output and fume load. Here's how to do it right: ● Install LEV hoods within 30cm of the welding arc to ensure effective fume capture ● Use adjustable extraction arms that can be positioned directly over the weld zone ● Ductwork should be straight and short to maintain airflow pressure ● Seal all joints to prevent leaks and maintain system integrity ● Install particle sensors to track air quality in real time Integrating LEV with PPE and Flashback Prevention Air extraction is only one side of the coin. Respiratory PPE and gas safety tools must also be factored in: ● Pair LEV systems with a Welding Helmet with Respirator when working in high-fume zones ● In heavy-duty applications or confined spaces, upgrade to a 3M Speedglas Helmet with powered air-purifying respirator (PAPR) ● Ensure your Auto Darkening Welding Helmet provides both visibility and respiratory protection for extended welding tasks

4. ● Include flashback arrestor testing as part of your routine air quality assessments—gas system leaks can increase toxic exposure when ventilation is weak LEV Maintenance Checklist A top-tier system is only as good as its upkeep. Schedule these monthly and quarterly checks: ● Inspect hoods and arms for obstruction or physical damage ● Clean or replace filters based on particle load ● Measure airflow rates using a calibrated anemometer ● Confirm no negative pressure zones or recirculated air ● Log servicing dates in your maintenance register Real-World Benefits of LEV Systems ● Fewer sick days: Workers report fewer headaches and respiratory symptoms ● Lower insurance premiums: Enhanced safety procedures can cut overhead

5. ● Pass inspections easily: Auditors favour well-documented ventilation systems ● Boost productivity: Comfortable welders stay sharper, longer Safety Isn’t Just About Ticking Boxes Australian welding standards often set the minimum, not the benchmark. To truly protect your team, look beyond compliance. Invest in systems that capture the full picture—from fume extraction to flashback arrestor testing to smart PPE. The Queensland incident is a tragic reminder that safety delays can have fatal consequences. Your workshop is only as safe as the air your team breathes.