Hand Tools - Non-sparking tools

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• What is a “non-sparking” tool?
• What is the most important thing to know about “non-sparking” tools?
• What are the hazards of both “sparking” and “non-sparking” tools?
• How should I use and maintain “non-sparking” tools?
• What is the best safeguard against incidental explosions?

What is a “non-sparking” tool?

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“Non-sparking,” “spark reduced,” “spark-resistant,” or “spark-proof” tools are names given to tools made of metals such as brass, bronze, Monel metal (copper-nickel alloy), copper-aluminum alloys (aluminum bronze), or copper-beryllium alloys (beryllium bronze).

X-Spark contains other products and information you need, so please check it out.

Commonly used hand tools are often manufactured of steel alloys. Preferred “non-sparking” metals have less tensile strength than steel used to make tools. A lower tensile strength means the metal has less strength or resistance to tearing apart when stretched under test conditions. It also means that these tools are softer, wear down more quickly than ordinary steel tools, and must be dressed more frequently.

What is the most important thing to know about “non-sparking” tools?

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Non-sparking tools also generate sparks, sometimes referred to as “cold sparks”. These cold sparks have a low heat level and do not ignite carbon disulfide, which has the lowest ignition point of any known substance. Therefore, while “non-sparking” tools may lower the risk of a spark, they do not eliminate the possibility of sparks. The name “non-sparking” is misleading because these tools are capable of producing a spark: the term “reduced-sparking tools” better describes these tools.

Non-metals like wood, leather, and plastic are suitable for some tools like shovels, scrapers or scoops and do not pose a friction spark hazard.

Non-sparking tools provide protection against fires and explosions in environments where there is a concern about sparks igniting flammable solvents, vapours, liquids, dusts, or residues.

NOTE: It is important to assess each situation carefully and use the appropriate tools for the hazards that are present. In some cases, “non-sparking” tools may still be able to produce a spark. Contact the tool manufacturer and the producer of the flammable material (for example) for recommendations and more information.

NOTE: It is also important to consider the metals used in the tools themselves. For example, beryllium has been associated with several health issues, including cancer. While exposure to beryllium dust is likely very low with the general use of non-sparking tools, it may be a consideration when grinding or polishing the tool itself.

What are the hazards of both “sparking” and “non-sparking” tools?

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Both “sparking” and “non-sparking” materials can cause ignition. Two types of hazards are associated with tools manufactured of either material:

1. Ignition by friction, with impact on each other or on other materials such as steel or concrete, in which an “ordinary” (mechanical or frictional) spark is generated. All tools can ignite flammable mixtures by sparks generated by friction or impact. However, this issue is true only when the generated spark is incendive: that means a spark that has to have enough heat content (i.e., enough mass and sufficiently high temperature) and has to last long enough to heat a flammable air-vapour mixture above its ignition temperature. This situation is more likely in the case of sparks formed when using a metal grinder than a spark generated when a hammer strikes a metal.
2. Ignition by a chemically-generated spark caused by the impact between certain metals and some oxygen-containing substances (such as rust, which is iron oxide).

How should I use and maintain “non-sparking” tools?

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Follow the guidelines below to reduce the risk of explosion and fire.

• Make sure all “non-sparking” tools are kept clean and free from ferrous or other contaminants, which may hamper the reduced or non-sparking properties.
• Select the right-sized tool for the task (such as the wrench opening to the nut). The right fit will help prevent the tool from slipping, reducing the chance of a spark.
• Inspect tools for wear, chips, or damage. 
• Use a non-sparking tool made of material that is compatible with the workpiece material.
• Do not use non-sparking hand tools in direct contact with acetylene, which may form explosive acetylides, especially in the presence of moisture.
• Use local or mechanical ventilation systems as appropriate to remove hazardous materials, dusts, and vapours from the workplace.
• Non-sparking tools will need to be redressed more often. Follow normal safety procedures when sharpening non-sparking tools such as the provision of eye and face protection, adequate extraction and dust collection facilities.

What is the best safeguard against incidental explosions?

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Follow safe work procedures. Always evaluate a job to be done in any hazardous environment. Use tools and equipment that eliminate ignition, such as electric motors that are certified as “explosion proof” for use in most hazardous work locations or non-sparking tools with proper use and maintenance. Keep in mind that there are no truly non-sparking tools. In any work where flames are used, or sparks are produced, make sure that an explosive atmosphere does not develop. Such atmospheres include flammable vapour-air mixtures and organic dust clouds like flour or coal dust. Isolation, ventilation and purging are methods of ensuring a safe working atmosphere. Use explosimeters in the workplace to monitor hazardous environments.

Refer to OSH Answers General Hand Tool Operation for more tips.

• Fact sheet last revised: -01-02

Non-sparking tools: Common Misconceptions You Need To Know

The following are some of the misconceptions about non-sparking tools that we have come across through interactions with industrial companies:

1. Non-sparking tools do not generate any spark

Non sparking tools are made of metal, and as a result, they do generate sparks. The difference between non-sparking tools and steel tools is the energy of the spark they generate.

The low energy of the sparks is the result of the special alloys in the composition of non-sparking tools.

2. Copper Beryllium (Cu-Be) tools are more expensive than Aluminum Bronze (Al-Bron) tools

Even if Cu-Be tools are around 30% more expensive than Al-Bron non-sparking tools, they are 40 to 50% harder. As a result, Al-Bron non-sparking tools may be a more expensive option over time considering you might need to replace them more often.

Depending on the frequency of use, using Cu-Be non-sparking tools may be a more economical option in the mid to long run.

3. Plastic coated tools are safe to be used in explosive work environments

Even if plastic coated tools are likely safer than steel tools, they can´t considered to be a safe option considering that it is not possible to coat all active parts of a tool.

 As a result, they are called spark reduction tools but not non-sparking tools. Their use is not recommended for the following reasons:

They do not avoid the risk of explosion

The plastic coating is susceptible to become damaged, further increasing the exposed areas

The standard EN -1 prohibits the use of steel made tools in most zones and groups of gas.

4. Cu-Be non-sparking tools are carcinogenic and therefore represent a health hazard

We have found out that there is some confusion about the impact that Cu-Be non-sparking tools could have in the user´s health.

It is true that beryllium in the form of dust, inhaled continuously over long periods of time has been proven to be cause lung cancer (for example in foundries where this alloy is melted and appropriate safety measures are not in place).

However, there is no evidence or recorded cases about Cu-Be non-sparking tools causing any cancer. Main reasons are:

Cu-Be has only 2% of beryllium in its composition.

It is not in powder form, so you do not inhale it.

The exposure is minimal.

It is for the above reasons that there is no country in the world that has banned the use of this alloy.

5. Cu-Be non-sparking tools are always the safest option

Even if Cu-Be non-sparking tools are generally the safest option, there is one exception: the presence of Acetylene gas.

Even if Acetylene is a gas in the IIC group (and therefore safe for Cu-Be non-sparking tools), the gas reacts with any alloy with a copper composition higher than 65%, creating a new highly explosive compound called copper acetylide.

As both Cu-Be alloys and Al-Bron contain more than 80% of copper, they must never be used in acetylene environments. In such environments, steel tools would likely be safer than Cu-Be non-sparking tools.

For such environments, EGA Master has developed an alloy called ACETILEX®, which have less than 65% of copper in their composition. As a result, ACETILEX® non-sparking tools are the only completely safe alternative on the market for working in environments with acetylene.

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AMPCO Safety Tools: Non-Sparking, Non-Magnetic Hand Tools

Non-Sparking Hazmat Kits

Safety experts recommend that you store your Non-Sparking tools separately from your standard tools.  This improves workplace safety, minimizes contamination and makes it easier to find your safety tools when you need them most!  AMPCO meets this need by offering a variety of standard or custom kits. Mix & Match with any tool – buckets, boxes and roll-up pouches.  A tool for every purpose and a kit for any job.

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Contact us to discuss your requirements of Non Sparking Tools. Our experienced sales team can help you identify the options that best suit your needs.

Non-Sparking Tools - Safety Tools

Non-sparking tools are used in offshore, petrochemical plants, mining, shipbuilding, and refineries, just to name a few.

These tools include various categories of tools; from handheld tools such as hammers and wrenches all the way to pneumatic cutting, grinding, and surface preparation tools.

These types of pneumatic tools fall under a specialized category at TFT and can be found under TFT-PNEUMATIC – Safety Tools.

They are ideal for:

Surface preparation in pipe repair

Beveling

Coating maintenance

Steel Grinding

Composite wrap pipeline repair

Weld seam removal

Pipe cutting

Drilling deck projects

Grating removal

Cutting stuck bolt heads

Their Certification for use in Explosive Environments and being explosion-proof quality makes them the industry standard for these applications. Here’s a demo of a surface preparation exercise by removing corrosion paint and some metal off a steel pipe.

What are Non-Sparking Tools?

The name non-sparking comes for the quality of not producing sparks when in contact with metal. So depending on the category all of these tools are made of non-ferrous materials, which means they don’t contain iron. Iron is the main reason why hot sparks are created when you grind metals.

Using a tool made of non-sparking material eliminates the risk of ignition in environments where there are flammable liquids, vapors or dust. This is why these specialty tools are ideal for use in closed spaces. These are safety tools that are needed in all industries where explosive or flammable environments are present.

Most spark-free tools are made of materials and alloys like copper-beryllium alloys, bronze, brass and even smaller tools made out of plastic, leather or wood can technically be considered non-sparking. But these are the lower range of spark-free tools available. In general, these materials (metals) are softer, so they don’t last much time in heavy-duty applications.

Hand power tools

These are things like drills, impact wrenches, and of course grinders, which are the tools that produce the most friction and thus a risk of ignition. The certified cold work grinders provided by TFT Pneumatic Safety Tools are within the category of non-sparking hand power tools and do not pose any of the risks associated with traditional tools/grinders.

In order for a grinder to fit the category of non-sparking, the grinder must be a certified cold work pneumatic grinder. Normally connected to a 90 PSI compressor, we have several grinders for different types of applications of various sizes and styles.

Rotating files and discs

Depending on the application, the array of options really opens up.

Our rotating files and grinding discs are so powerful and safe to use is their main component: a proprietary alloy based on tungsten carbide, which makes it comparably as hard as a diamond. Other trade secrets include Patented material removal patterns, among a few other things.

The design of the teeth increases the longevity of the rotating files and disc, where users of these tools say they last one hundred times longer than a regular high quality grinding file or disc.

Safe to Use in Explosive Environments

These cold work tools are compliant with ATEX Guidelines.

ATEX is the name given to the two European Directives that control explosive environments in any industry. One directive refers to the safety of the workers in hazardous environments, and the second Directive refers to the safety of the equipment used in these environments.

At the time of this writing, there is no equivalent regulation to the ATEX Certification in the US as EU regulations are far more advanced. However, the ATEX Certification is recognized globally in the industry, even if there is no official standard in the US, as there are no directives for mechanical risk ignitions, specifically by OSHA (Occupational Safety and Health Administration).

Regarding the need for these tools, OSHA’s website cites:

Iron or steel hand tools may produce sparks that can be an ignition source around flammable substances. Where this hazard exists, spark-resistant tools made of non-ferrous materials should be used where flammable gases, highly volatile liquids, and other explosive substances are stored or used.

TFT Pneumatic’s cold work tools are safe to use in Class 1 Div 1&2, and ATEX Gas Zones 1 & 2, dust zones 21 & 22. This means that using these tools eliminate the need for a hot work permit, pressurized welding enclosures, fire watches, shutdowns, nitrogen purging to perform any kind of mechanical operation, saving you time and costs.

Benefits of Using Non-Sparking Tools in Explosive Environments

Sparkless tools are quite simply the only way to properly do work in any explosive environment. But having the right tools for difficult jobs reduces costs and provides a specialized worker with adequate tooling.

No Shutdown Necessary

Something really important about these tools is that they let you do maintenance work without the need for a shutdown. By eliminating the risk of an explosion, the everyday operations can go on as normal.

While the tools may be used during the TAR, they are even more useful year-round or Pre – TAR.

Additionally, there is no need to build habitats, pressurized welding enclosures or setup fire watches during operation time. These certified cold work tools are an absolute necessity and investment for continuous operation.

No Abrasive Embedding

In the case of surface preparation, as you saw on the video, we used the A- Big Papa Rotating File, along with a FUJI pneumatic die grinder. What it did was remove the corrosion off the pipe and provide surface prep for a surface coating such as paint or a wrap.

The file is made out of a proprietary alloy based on Tungsten. So, the entire process does only increases the temperature of the pipe by about 5F.

Surface Preparation

Among the many benefits of using TFT-PNEUMATIC’s surface prep tool are the following:

Ability to work in Class 1 Div 1&2 and EX Classified Areas.

Roughness Profile 2.5 mils

Equivalent to common blast standards referred to in SSPC-SPC 10 (SA 2 ½ near white) Nace No. 2.

Avoid postponements, hot work permits, shutdowns, habitats PWE, and fireguards.

Perfect for year-round maintenance jobs!

Perfect for reducing prep work prior to TAR’s!

Best Non-Sparking Tools

The best non-sparking tool is the one that gets the job done faster and with the least expense possible. While traditional tools are surely cheaper, the expenses to use them far exceed their benefits in most cases.

For example, in an Offshore Platform, say you need to remove a welded structure to the deck. While a torch is cheaper, the cost of shutting the unit down may exceed the hundreds if not millions of thousands of dollars in a matter of hours or a few days. Surely the torch is cheaper, but when you add up the cost of a hot work Permit, shutdown, downtime, and so on. TFT-PNEUMATIC Safety Tools are incredibly cheaper. Most of our customers have the tools to pay for themselves within the very first job and can continue to use them for a number of years.

For example, for a ship hull repair job, you need to consider the equipment you will be using. A small grinder Certified Cold Work grinder can get the job done faster by only preparing the rusted surface, feathering its way in and out. Alternatively, a needle gun with a brass needle will never achieve the quality of surface TFT-PNEUMATIC Safety Tools will, and is about 200 times slower in speed. Perhaps using a sandal blaster is an option. But they are geared towards large areas and will remove perfectly good paint and create a big mess.

For more information, please visit Non Sparking Tools Suppliers.