Protecting Workers in Explosive Environment Using ATEX Tools

In some environments, the slightest spark can cause an explosion. These potentially explosive environments occur when dust, vapor, or gas mix with air and include grain silos, petrochemical plants, garages where paint spraying takes place, etc. When working in these environments, worker safety requires the use of properly designed tools as well as protective equipment. ATEX (Atmospheres Explosibles) certification is the main way companies can be sure that the tools they provide will not endanger workers.

The Dangers of Explosive Environments

Explosive hazardous environments can occur across a variety of industries. While we tend to think of obviously flammable substances such as petroleum, some very common substances, such as flour, can present an explosion hazard.

In these environments, the slightest spark can cause a fire or explosion. Explosions are more likely in confined spaces, but even in the open air, a dangerous fire can start. In a dry environment, the fire can spread to nearby brush creating a wildfire.Explosions occur when a specific fuel-to-air mixture ratio is reached, and someone applies even a small spark. This produces a fireball, high heat, and shock waves which have resulted in loss of life as well as severe injury and damage to the built environment. On  August 23 in Turkey, a grain silo exploded while workers unloaded a ship. In this case, the compression of dust, rather than a spark, caused the explosion. This damaged 13 silos and outbuildings and injured 12 people, three of them seriously.

To highlight the danger in workshops and similar, a man using a brush-type drill died when he loosened a fuel panel on a Cessna in a general aviation hangar. Aviation also requires ATEX tools to protect workers and aviation hobbyists from risks.

It is important to use ATEX-certified tools in all potentially explosive environments, even for short-duration tasks like minor repairs to agrain elevator.

What Is ATEX Certification?

ATEX in this context refers to the  Atmospheres Explosible Directive 2014/34/EU. It might seem strange for US companies to use an EU standard, but the standard is extremely high and helps ensure the safety of workers. The standard has become recognized internationally and provides a practical guide for worker safety and customer reassurance - it exceeds U.S. standards. Also, companies who wish to sell in any EU country must meet 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 produce ATEX standards. There's also a related workplace directive that sets out the responsibilities of employers, such as providing proper ventilation and PPE.

The ATEX certification covers all kinds of tools including reciprocating saws, impact wrenches, nut runners, magnetic drills, etc. There are also standards for personal protective equipment and workplace issues such as ventilation.

What Makes ATEX Tools Different?

Most power tools produce sparks as part of their normal operation. Often, these sparks go unnoticed by the user, especially if working in a well-lit environment.

Electrical arcing between the carbon brush and the commutator causes these sparks. They aren't considered a problem. However, excessive sparking or a sudden increase in sparking may indicate a problem with the tool, such as a loose brush. Home power tools typically have this design, and many industrial tools also use it. The sparking is not a problem in most cases, but when working in a potentially explosive environment, this becomes lethally dangerous.

Nonsparking tools use a different type of motor called a "brushless" motor. Instead of transferring energy mechanically, these motors transfer it electronically, which avoids the risk of sparking. This design enables users to operate these tools in explosive environments with minimal risk. However, users should still wear protective equipment and maintain the tools properly to avoid issues.

ATEX tools also have to be manufactured to high standards. There are rules about quality assurance to ensure that every tool that ships is safe and ready to be used. The workplace guidelines are useful to help employers give their workers the best chance to stay safe.

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How Do I Know if a Tool Is ATEX Certified?

ATEX tools carry the Ex symbol and a label that indicates its classification. This classification covers whether the tool is intended for surface or underground use, whether it is rated for an atmosphere containing gas, vapors, or mist, or an atmosphere containing dust, and what zone it is rated for.

ATEX certification covers multiple zones. For example, 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 is rated for. You need to select the right tools with this in mind. The tool has a temperature rating, and users should not exceed this temperature. Elevated temperature increases the risk that a spark will start a fire substantially.

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 centigrade.

Fake certification for ATEX tools can occur. To avoid it, always purchase your tools from a reputable manufacturer and vendor. Talk to the vendor first about the technical specifications and cross-check their knowledge. Look at the manufacturer too, and when you receive the tools, make sure that the Ex label is accurate, matches what you were told about the tool, and does not appear to have been tampered with. This kind of fraud is rare, but when it does occur, 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 who operate within the environment and a restricted boundary to keep untrained and unauthorized personnel at a safe distance.
• Proper ventilation to prevent the build-up 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.
• Use 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 knows the dangers.

Everyone who works 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 does occur. 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. provides a full range of ATEX-certified tools ranging 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 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.