Client Background
The client operates a steel foundry across two sites and required a comprehensive DSEAR assessment covering 20+ distinct operational areas.
Client Problem
The steel foundry operates multiple processes involving flammable and combustible materials, including combustible wood dust, flammable liquid coatings, natural gas distribution systems, and multiple flammable storage locations. The potential for electrostatic discharge in areas handling insulating materials added complexity.
Assessing 20+ separate operational areas, each with distinct hazards and control requirements, presented a significant challenge in ensuring comprehensive DSEAR compliance.
Client Objectives
The client required a complete DSEAR risk assessment covering all operational areas, identification and classification of hazardous zones in accordance with ATEX directives, and practical recommendations that could be implemented within an operational steel foundry environment.
To meet these objectives, Sigma-HSE undertook a detailed multi-site assessment of all operational areas.
Insights
Sigma-HSE conducted a comprehensive site assessment considering the likelihood and persistence of explosive atmospheres and potential ignition sources (electrostatic discharges, mechanical sparking, non-ATEX equipment and hot work activities). Sigma-HSE also assessed process interactions, existing control measures, zone classifications for gas, vapour, and dust atmospheres. Lastly, a basis of safety for each process and area was established, covering both normal and abnormal operations.
Outcomes
This thorough assessment process resulted in a clear and actionable set of outcomes for the client.
Sigma-HSE delivered a comprehensive recommendation report comprising over 60 actionable points.
Key outcomes included:
- Issues such as the accumulation of wood dust in the workshop, propane storage, cylinder separation, and substance storage were identified for rectification.
- Frameworks including Safe Systems of Work for all DSEAR-relevant operations, static control measures (footwear, clothing, flooring, earthing), ventilation and LEV requirements, appropriate ATEX equipment ratings, and regular inspection schedules were created.
- Each recommendation included specific technical standards (BS EN 60079-32, EN1149-5:2018, BS EN 60079-10-1, BS EN 60079-10-2 IP ratings) and authoritative guidance (HSG176, HSG71).
The assessment provided the client with a clear roadmap to DSEAR compliance across both sites, enabling continued safe operation while managing explosive atmosphere risks to as low as reasonably practicable.
