The use of mechanical tools in hazardous areas

Purpose of note
From time to time concern is expressed about the possible risk of frictional sparking caused by the use of steel tools in hazardous areas. This note attempts to put this risk in perspective and make a positive proposal on acceptable practice.

It is recognised that frictional sparking between certain materials can ignite a flammable gas with only a very small amount of mechanical energy. The classic example is the early cigarette lighter, which with a flick of the thumb ignited petroleum vapour by rotating a serrated steel wheel against a flint. The materials which cause a lot of concern are light alloys because heating small particles of these materials causes a thermal reaction which produces a higher than expected temperature. The use of such alloys in electrical equipment for use in hazardous areas is discouraged in the General Requirements [IEC 60079-0] which imposes limits on the use of aluminium, magnesium, titanium and zirconium in Zone 0 and 1. Interestingly there are no restrictions on the use of these alloys for Zone 2 applications except for fans and ventilating screens, presumably it is accepted that the risk of frictional sparking causing ignition is low enough for it to be ignored.

Most of the available technical evidence supports the view that ignition by small hot particles is related to spark ignition energy and not to ignition by hot surfaces. That is the IIC gases [hydrogen, acetylene and carbon disulfide] are easier to ignite than IIB and IIA gases. The minimum level of impact required to produce ignition is difficult to establish but a glancing blow is thought to be most incendive. A recent analysis of the available literature plus some experimental evidence carried out by a German Test House suggests that a steel upon steel impact has to be greater than 3Nm for ignition to occur. At 10Nm there is a 10% risk of igniting a IIC gas and a very low probability of igniting a IIB gas. [3Nm is created by a 1Kgm weight falling through 30cm]. These are significant levels of impact and are not likely to occur unintentionally in the maintenance and inspection of instrument systems.

In the conditions where maintenance is normally performed hydrogen is unlikely to achieve the ideal concentration for ignition [20% by volume in air]. Hydrogen has very low density and low viscosity and hence disperses rapidly on release in a non-enclosed location. It has to achieve a concentration in excess of 10% before its ignition energy is less than that of ethylene, hence in the majority of Zone 1 locations where servicing of instrumentation is carried out, it becomes effectively a IIB gas.

The use of tools
The use of those tools normally used in servicing instruments is not likely to produce an impact which will could create a frictional spark capable of igniting any gas/air mixture. The weight of such tools as screwdrivers and keys to socket headed screws [Allen keys] are such that they would have to achieve a significant velocity before producing an impact of 3Nm. The use of a correctly chosen socket spanner is a safer practice than the use of non-steel alternatives which are frequently unsatisfactory because they are not sufficiently robust. It is advisable to avoid the use of rusty tools, but this is normal practise. This manually operated type of tool is normally considered capable of causing a single spark. Activities, which cause multiple sparks such as grinding and sawing, do require special consideration, since they pose a greater risk.

There are obvious areas of risk, normally outside the activities of the majority of instrument technicians such as the use of a hammer and cold chisel to remove rust from an enclosure or the dismantling of aluminium scaffolding , both of which require some thought.

Guidance within IEC standards on the use of tools is not available. Several petroleum industry codes do give guidance and they all suggest that there is no significant risk. A CENELEC standard EN 1127-1 has an informative Annex A which takes an extremely cautious and impracticable view on the subject. It proposes that the use of steel tools should not be permitted in a Zone 1 without a gas clearance certificate where the gas producing the risk is a IIC gas. Possibly this prohibition can be justified if the tools involved are heavy and of the kind which might be necessary for work on major pieces of mechanical equipment. A blanket approach, which includes the tools normally, used by an instrument engineer is not justifiable.

EN 1127-1 adds a number of IIB gases to the prohibition. These are hydrogen sulfide, ethylene oxide and carbon monoxide. Why these particular gases are singled out is not apparent and it would be interesting to find the basis of this selection.

The use of steel tools of the type normally used to maintain instruments does not cause an unacceptable risk of ignition due to frictional sparking in Zones1 and 2 whatever the gas/air mixture creating the possible hazard.

There is a need for anyone working in hazardous areas to be aware of the risk associated with frictional sparking, but the careful use of steel tools is acceptable

In anticipation of a possible comment, I realise that gases are not classified and that it is equipment, which is classified for use with certain gases. However if this note was written using phrases such as a ‘gas which requires the use of IIC equipment’ it becomes even less comprehensible. This justifies the use of ‘IIC gases’ even though it is not pedantically correct.

Explore posts in the same categories: ATEX Directive, CENELEC, Explosion Protection, Hazardous Areas, IEC, IEC60079, Intrinsic Safety

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