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Protecting Workers in Explosive Environment Using ATEX Tools
In certain environments, even the tiniest spark can trigger an explosion. Such potentially explosive conditions arise when dust, vapor, or gas mixes with air. Examples include grain silos, petrochemical plants, and garages where paint spraying occurs. Ensuring worker safety in these settings requires the use of appropriately designed tools along with protective equipment. ATEX (Atmospheres Explosibles) certification serves as the primary method for companies to confirm that the tools they supply won’t endanger their employees.
The Hazards of Explosive Environments
Explosive hazardous environments span various industries. While we often associate flammable substances like petroleum with danger, common materials such as flour can pose an explosion risk as well.
In these environments, the smallest spark can ignite a fire or explosion. Explosions are more likely in confined spaces, but even outdoors, a dangerous fire can break out. In a dry setting, the blaze could spread to nearby brush, starting a wildfire. Explosions happen when a specific fuel-to-air ratio is achieved, and even a minor spark can set off a fireball, intense heat, and shockwaves—resulting in fatalities, severe injuries, and significant damage to structures. On August 23 in Turkey, a grain silo exploded while workers were unloading a ship. Here, the compression of dust, rather than a spark, caused the explosion. This destroyed 13 silos and outbuildings and injured 12 people, three critically.
To illustrate the danger in workshops and similar settings, 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 short-term tasks like repairing a grain elevator.
What Is ATEX Certification?
ATEX, in this context, refers to the Atmosphere Explosible Directive 2014/34/EU. It might seem odd for U.S. companies to adopt an EU standard, but the standard is exceptionally high and ensures worker safety. Recognized globally, it offers practical guidance for worker safety and customer reassurance—exceeding U.S. standards. Companies aiming to sell in any EU country must comply with this certification. It encompasses all equipment and protective systems meant for use in potentially explosive environments.
The European Committee for Standardization and the European Committee for Electrotechnical Standardization develop ATEX standards. There’s also a related workplace directive outlining employer responsibilities, such as proper ventilation and PPE.
ATEX certification applies to all types of tools, including reciprocating saws, impact wrenches, nut runners, magnetic drills, etc. Standards also exist for personal protective equipment and workplace issues like ventilation.
What Sets ATEX Tools Apart?
Most power tools generate sparks during normal operation. Often, these sparks go unnoticed, particularly in well-lit environments.
These sparks result from electrical arcing between the carbon brush and the commutator. Typically, they’re not an issue. However, excessive or sudden sparking might signal a problem with the tool, like a loose brush. Home power tools usually have this design, and many industrial tools follow suit. Sparking isn’t problematic in most situations, but in potentially explosive environments, it becomes fatally dangerous.
Nonsparking tools employ a different motor type 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. Still, users should wear protective gear and maintain the tools properly to avoid issues.
ATEX tools must adhere to stringent manufacturing standards. Quality assurance regulations ensure each shipped tool is safe and ready for use. Workplace guidelines help employers give workers the best chance at staying safe.
How Do I Know If a Tool Is ATEX Certified?
ATEX tools bear the Ex symbol and a label indicating its classification. This classification specifies whether the tool is intended for surface or underground use, whether it’s rated for atmospheres containing gas, vapor, or mist, or atmospheres containing dust, and what zone it’s rated for.
ATEX certification covers multiple zones. For gases, 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 inform you about the tool’s appropriate zone and the type of gas it’s rated for. You need to select the right tools accordingly. The tool has a temperature rating, and users should not exceed this temperature. Elevated temperature significantly raises the risk that a spark will ignite a fire.
For instance, the CS Unitec Pneumatic Reciprocating Saw is rated Ex II 2 GCt5. This means it’s suitable for zones 1, 2, 21, and 22 at temperatures up to 100 degrees Celsius.
Counterfeit ATEX certifications can occur. To avoid this, always buy tools from reputable manufacturers and vendors. Discuss the technical specifications with the vendor first and verify their knowledge. Check the manufacturer too, and upon receiving the tools, ensure the Ex label is accurate, matches what you were told, and hasn’t been tampered with. Although rare, fraudulent certifications can endanger workers and businesses.
Other Steps to Protect Workers
Using ATEX-certified tools is one of the most significant ways to protect your workers. However, there are additional measures you can and should take to safeguard your workforce and equipment. These include:
- Proper training for all workers operating in the environment, with restricted boundaries to keep untrained and unauthorized personnel at a safe distance.
- Proper ventilation to prevent pressure buildup that can lead to an explosion, even without 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 begins 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 associated dangers.
Everyone working in a potentially explosive environment should wear protective gear at all times and keep their workspace clean and clutter-free. 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 reduce the risk of a worker inadvertently choosing 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. Prevention is ideal, but having a plan for the worst-case scenario is essential.
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 proper safety equipment and, of course, training—but they can significantly contribute to worker safety. These are also high-quality, durable tools that will last and help your workers perform their jobs effectively.
Contact us today! You can trust our tools to keep your workers safe in the most hazardous environments.