Task $4$: Hazardous zoning

$4$ As part of their explosive atmosphere risk assossment the factory manager used their personal judgement and opinion to classify work arean into hazardous zones. They quickly decided to classily the whole building as Zone $1.$

$($a$)$ Explain why this may not be the correct decialon.

Note: Your answer must be based on the scenario only.

$($b$)$ What should the factory manager have considered when selting the zone classifications?

Note: You should support your answer, where applicable, using relevant information from the scensino.

$($c$)$ Assuming other hazardous zones exist within the whole building, what control measures should the factory managor consider within these hazardous zones?

Note: You should support your answer, where applicable, using relevant information from the scenani.

SCENARIOCover Up is an organisation specialising in powder coating matal components. Thay employ fivefactory workers, a factory manager, and hwo office workers between the hours of $8$am and $9$pm$.$They owna $400$m factory building located in a large industrial estate with a car park at the front.The factory floor is an open$-$plan area where items to be coated are brought in through a large metalroller shutter door. They are then stored on the floor or against the walls near the roller shutter doorprior to being worked upon. Also next to the roller shutter door is the main entrance door. This dooris also an emergency exit door that opens out into the car park.Itams that are powder coated can range from ducing components, household appllancas,automobile parts, and ironwork such as gates and bicycle frames.Localed on the faclory floor are various pieces of equipment used in the preparation of items beforethe coating process. This equipment consists of a free$-$standing pllar drill, a bench$-$mounted grindingwheel, a powered hack saw, and a larga workbench with various hand$-$operated tools. Evidenoe ofoverspray from the coating process can ba seen in many places on the factory floor. Some powderand dust accumulations can be seen on machinery. To the right of the factory loor, there is aninternal fire door leading into a corridor Workers must push hard to get this door open. The doorseal is frayed, and the door hinges have become bent.Leading off this coridor is an office, a kitchen area and tollet facilties. Advertising posters,certificates and framed pictures have been placed along this corridor wall, some of which partiallycOver fire noicesThe kitchen area, situaled opposite the offce is avalable for workers to use during thair breaks, Inthe kitchen area there is a micowave, sink, kattle, and a small wooden lable and upholstered chalrs.A labelled emergency exit door that opens out into the car park is located at the end of the coridor.As smoking is not allowed inside, some workers have a habit of wedging open the emergency exitdoor so that they can step outside to smoke a clgarette during theit breaks

While walking through the factory, office workers have noticed rodent droppings and evidence ofchewed cables The electrical system within the factory has never been replaced or upgraded sinceCover Up moved into the premises. A complete review and overhaul of tha electrical systerm is bingconsidered, as there are concems about interruption to production A pest control company will becontracted to regularly place rodent bait in$,$ and around, the factory.The powder coating processThe metal items to be powder coated are initially cleaned using degroasing solvents This is so thatthe powder coat will stick to the bare metal. In some instancas, the preparation and cleaning of themetal can be an aggressive process, involving shot blasting The purpose of this is to remove anyold paint or other residue, to return the work item back to baro metal.Using pneumatic electrostatic guns, the items are then covered with a dry coloured powder. For thepowder to attach to the workpiece an electrostatic method is used. As the powder leaves thepneumatic gun it is positively charged, whilst the item is negatively charged This causes the powderto stick to the metal. Itis then baked $($cured$)$ in a large oven to achieve a permanent smooth finishOnce the baking process is complete the items are removed from the oven, allowed to cool, and thenWrapped and packaged ready for despatch to customers

Pressure SystemA foxed air compressor, with a capacity of over $250$ bar litres is situated in the open air, outside thefactory. It is powered by a $400$v$,3-$phase electrical supply, with a screw compressor feeding an airrecaiver, protected by a pressure valve. t oparates at or above a $25$ bar pressure and has beenused by Cover Up for many years. When in operation it is very loud and creates hissing noises atvarious pipework connections. The information plate on the compressor has become difficult to read,but there is an operating procedure kept in the offica. The procedure states the operating limits ofthe unit, although the system itself has never been measured or checked b