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Protecting Workers in Explosive Environment Using ATEX Tools
In certain settings, even the smallest spark can trigger an explosion. Such potentially explosive environments arise when dust, vapor, or gases mix with air, including locations like grain silos, petrochemical plants, and spray painting garages. Ensuring worker safety in these environments requires the use of properly designed tools along with appropriate protective gear. ATEX (Atmospheres Explosibles) certification is a key method for companies to guarantee that the tools provided won’t endanger employees.
The Hazards of Explosive Atmospheres
Explosive hazardous environments can be found across various industries. While we often think of highly flammable substances like petroleum, common materials such as flour can also pose an explosion risk.
In these conditions, even the tiniest spark can ignite a fire or explosion. Explosions are more likely to happen in enclosed spaces, but even outdoors, a dangerous blaze can start. In dry conditions, the fire can spread to nearby vegetation, potentially causing wildfires. Explosions occur when a precise fuel-to-air mixture ratio is achieved, and a small spark is introduced. This generates a fireball, intense heat, and shockwaves, leading to fatalities, severe injuries, and significant damage to structures. On August 23 in Turkey, a grain silo exploded while workers were unloading a ship. In this case, the compression of dust, rather than a spark, caused the explosion. This destroyed 13 silos and adjacent buildings, injuring 12 people, three of them critically.
To emphasize the danger in workshops and similar places, a man using a brush-type drill died when he loosened a fuel panel on a Cessna in a general aviation hangar. Aviation also demands ATEX tools to safeguard workers and aviation enthusiasts from risks.
It’s crucial to use ATEX-certified tools in all potentially explosive environments, even for brief tasks like minor repairs to a grain elevator.
What Is ATEX Certification?
ATEX in this context refers to the Atmosphere Explosible Directive 2014/34/EU. Although it might seem odd for US companies to adopt an EU standard, the standard is exceptionally rigorous and ensures worker safety. The standard has gained international recognition and serves as a practical guide for worker safety and customer reassurance—it surpasses US standards. Additionally, firms aiming to sell in any EU nation must comply with this certification. It covers all equipment and protective systems intended for use in these potentially explosive environments.
The European Committee for Standardization and the European Committee for Electrotechnical Standardization create ATEX standards. There’s also a related workplace directive that outlines employer responsibilities, such as providing adequate ventilation and personal protective equipment (PPE).
ATEX certification applies to all sorts of tools, including reciprocating saws, impact wrenches, nut runners, magnetic drills, etc. There are also standards for personal protective equipment and workplace issues like ventilation.
What Sets ATEX Tools Apart?
Most power tools produce sparks as part of their normal operation. Often, these sparks go unnoticed by the user, especially in well-lit environments.
Electrical arcing between the carbon brush and the commutator causes these sparks. They’re not usually a concern. However, excessive sparking or a sudden increase in sparking could signal a problem with the tool, such as a loose brush. Many home power tools and several industrial tools have this design. The sparking isn’t typically an issue, but when working in potentially explosive environments, it becomes dangerously lethal.
Nonsparking tools use a different type of motor called a "brushless" motor. Instead of transferring energy mechanically, these motors transfer it electronically, eliminating the risk of sparking. This design allows users to operate these tools in explosive environments with minimal risk. However, users should still wear protective gear and maintain the tools properly to avoid issues.
ATEX tools must also be manufactured to high standards. There are rules regarding quality assurance to ensure that every tool shipped is safe and ready for use. The workplace guidelines are valuable for helping employers give their workers the best chance to remain safe.
How Do I Know If a Tool Is ATEX Certified?
ATEX tools carry the Ex symbol and a label indicating its classification. This classification covers whether the tool is intended for surface or underground use, whether it’s rated for an atmosphere containing gas, vapors, or mist, or an atmosphere containing dust, and what zone it’s rated for.
ATEX certification covers multiple zones. For instance, for gas, mists, or vapors:
- Zone 0: Flammable gas, vapor, or mist is present frequently, continuously, or for long periods.
- Zone 1: Flammable gas, vapor, or mist is likely to occur occasionally in normal operations.
- Zone 2: Flammable gas, vapor, or mist is not likely to occur during normal operations but may occur for a short period.
For dust:
- Zone 20: Combustible dust is present frequently, continuously, or for long periods.
- Zone 21: Combustible dust is likely to occur occasionally in normal operations.
- Zone 22: Combustible dust is not likely to occur during normal operations, but may occur for a short period.
Understanding the ATEX Label
The ATEX label will tell you what zone a tool is appropriate for and what kind of gas it’s rated for. You need to choose the right tools with this in mind. The tool has a temperature rating, and users should not exceed this temperature. Elevated temperature significantly increases the risk that a spark will start a fire.
For example, the CS Unitec Pneumatic Reciprocating Saw is rated Ex II 2 GCt5. This means it’s appropriate for zones 1, 2, 21, and 22 at temperatures of up to 100 degrees Celsius.
Fake certification for ATEX tools can occur. To avoid it, always buy tools from a reputable manufacturer and vendor. Discuss the technical specifications with the vendor first and cross-check their knowledge. Investigate the manufacturer as well, and upon receiving the tools, ensure that the Ex label is accurate, matches what you were told about the tool, and doesn’t appear to have been tampered with. This type of fraud is rare, but when it happens, it can endanger your workers and business.
Other Steps to Protect Workers
Using ATEX-certified tools is one of the biggest ways to protect your workers. However, there are other steps you can and should take to help protect your workers and equipment. These include:
- Proper training for all workers operating within the environment and setting boundaries to keep untrained and unauthorized personnel at a safe distance.
- Proper ventilation to prevent the buildup of pressure that can lead to an explosion, sometimes without the need for a spark.
- Keeping work areas clean and safely storing all flammable materials.
- Using appropriate personal protective equipment, including fire-resistant clothing, safety glasses, and static-resistant clothing and shoes.
Protecting workers starts with a risk assessment and training to highlight and understand the specific dangers of the environment. This way, everyone involved knows how to reduce the risk of an explosion and understands the dangers.
Everyone working in a potentially explosive environment should wear protective gear at all times and keep their work area clean and free from clutter. Educate workers on the correct tools, especially in environments with multiple hazards or zones. In some cases, specific tasks might require specific tools. When selecting ATEX tools, it’s best to “overbuy†and use tools rated for the most hazardous zone on site to lower the risk of a worker not paying attention and picking up the wrong tool. Store tools for explosive environments separately from those used in safer areas to avoid confusion.
Companies should also develop a disaster response plan to ensure safe evacuation and minimize danger if an incident occurs. It’s best to prevent a fire or explosion in the first place, but you need to have a plan for if the worst happens.
Let Us Provide You With ATEX-Certified Tools
International Air Tool and Industrial Supply Co. offers a full range of ATEX-certified tools, from impact wrenches to rotary hammer drills to axial fans. We use ATEX certification to provide the best possible protection for you and your workers.
We specialize in power tools for the oil, gas, and energy industries. However, our certified tools are also suitable for various hazardous environments. We also provide clear instructions to help workers use the tools correctly.
Our tools can’t protect your workers alone – you also need the correct safety equipment and, of course, training – but they can go a long way toward keeping your workers safe. These are also high-quality, durable tools that will last and help your workers do their jobs effectively.
Contact us today! You can trust our tools to keep your workers safe in the most hazardous environments.