Client Background
A leading UK logistics and warehousing brand planned to introduce a new product into their storage facilities.
Client Problem
This product had the potential to generate combustible dust during handling and storage, raising concerns about compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR).
Client Objectives
The client needed to understand DSEAR implications, determine if their existing facilities were suitable, or identify necessary alterations to ensure safe storage. A further complication was that the product's Safety Data Sheet (SDS) lacked essential dust flammability characteristics.
Insights
Strategy
To address the client's needs comprehensively, we implemented a strategic, multi-step approach:
Material Hazard Characterisation
Recognising the critical gap in safety information, our first recommendation was to determine the specific dust flammability properties. The client’s product samples were tested at Sigma-HSE’s accredited laboratory facilities. This provided crucial data such as explosibility characteristics (Kst, Pmax), Minimum Ignition Energy (MIE), and layer/cloud ignition temperatures, which are essential for a robust DSEAR risk assessment.
DSEAR Risk Assessment & Facility Evaluation
Armed with the material-specific data, our engineers conducted a thorough DSEAR Risk Assessment of the client’s warehousing facility.
This involved:
• Identifying areas where combustible dust atmospheres could form.
• Performing Hazardous Area Classification (HAC) to define the extent and type of any zoned areas (e.g., Zone 21, Zone 22).
• Assessing potential ignition sources, including existing electrical equipment and risks from static electricity.
• Evaluating current control measures and identifying any shortfalls
Results
Data-Driven Safety
The laboratory testing furnished the client with essential, previously missing, dust flammability data from their SDS, enabling informed risk management.
Compliance & Safety Enhancements
The DSEAR Risk Assessment identified the critical need for an LEV system, guiding the client to invest in appropriate engineering controls to ensure safer storage conditions and DSEAR compliance.
Cost-Effective Solutions
By thoroughly assessing the actual risks and applying relevant guidance, we confirmed that the client’s existing IP65 lighting was suitable for the determined dust zones, avoiding unnecessary expenditure on ATEX-rated replacements. This freed up capital that could be re-allocated towards the new LEV system.
Operational Guidance
Sigma-HSE provided clear parameters for safe storage volumes and durations, specifically addressing self-heating risks, allowing the client to handle the new product confidently and safely.
