What is ATEX Directive?

ATEX Directive stands for “ATmosphere EXplosible” Directive. It is a set of regulations established by the European Union to ensure the safe use of equipment in potentially explosive environments, such as those found in oil and gas production, chemical manufacturing, and other industries.

The ATEX Directive is implemented through the Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) which includes the classification of hazardous areas and the specific requirements for equipment and protective systems used in these areas.

The directive sets out specific requirements for the design, construction, and testing of equipment and protective systems used in these environments. It also establishes a framework for the certification of equipment and the training of personnel who work with it.

What is ATEX Zone?

ATEX Zone is a classification system used to identify areas where there is a risk of explosion due to the presence of flammable gases, vapours, dusts, or powders. The ATEX Directive then identifies the classification of equipment that can be used safely within these zones.

Typically, the higher the risk or prevalence of flammable substances, the stricter the safety rating of the electrical or mechanical equipment needs to be.

The typical considerations for ATEX fall into the risk of explosive atmosphere, the temperature classification of the equipment and the type of substance.

Equipment used in these zones must be certified as compliant with the ATEX Directive, and personnel must be trained in the safe use of the equipment.

ATEX Requirements

If you have read this far and are thinking ‘this sounds familiar’ you may have already heard of ATEX. ATEX requirements form part of DSEAR, specifically in relation to explosive atmospheres that occur due to the presence of flammable gasses or combustible dust mixed in air.

During a DSEAR Assessment, we inspect the areas and processes to determine if the equipment is suitably rated for the atmosphere, in some cases IP rated equipment can be sufficient for dusty environments.

For small sites, we can review all electrical and mechanical equipment for this process. For larger sites, we sometimes recommend that another ATEX BS EN 60079-17 inspection is completed. This is slightly another separate subject, but we can give confidence in general during the DSEAR Assessment. ATEX certification improves safety and protects workers from explosive risk.

ATEX Temperature Classification

ATEX temperature classifications are used to identify the maximum surface temperature that equipment can reach without creating a fire or explosion hazard in a potentially explosive atmosphere. The temperature classifications are defined in the ATEX Directive and are based on the ignition temperature of the specific gas or dust present in the environment.

The ATEX temperature classifications are as follows:

T1: maximum surface temperature is 450°C
T2: maximum surface temperature is 300°C
T3: maximum surface temperature is 200°C
T4: maximum surface temperature is 135°C
T5: maximum surface temperature is 100°C
T6: maximum surface temperature is 85°C

It is important to note that the surface temperature of equipment should not exceed the classification temperature for more than 10 seconds during normal operation, and for no longer than 30 seconds during abnormal operation.

It is also important to note that the temperature classifications only apply to the equipment surface and not to the internal temperature. And the temperature classification of equipment must be determined by a qualified person, taking into account the specific characteristics of the location and the type of activity being carried out.

ATEX Substance Classification

ATEX substance classification is used to identify the types of flammable gases, vapours, dusts, or powders that may be present in a potentially explosive environment. The classification system is defined in the ATEX Directive and is based on the physical and chemical properties of the substance and its ignition temperature. The classification system is divided into two main categories: gases and dusts.

Gases

Gases are classified into two groups, Group I and Group II, depending on their ignition temperature.

Group I: Gases with an ignition temperature below 135°C (e.g., methane, propane)

Group II: Gases with an ignition temperature above 135°C (e.g., butane, hydrogen)

Dusts

Dusts are classified into three groups, Group III, Group IV, and Group V depending on the particle size and the specific properties of the dust.

Group III: Dusts with particle size greater than 420 microns (e.g., coal dust, wood dust)
Group IV: Dusts with particle size less than 420 microns (e.g., flour, sugar)
Group V: Dusts that do not belong to the previous groups (e.g., metal dust, metal oxide dust).

ATEX Ignition Temperature

ATEX ignition temperature is a term used in the ATEX Directive to identify the temperature at which a flammable gas, vapor, dust, or powder will ignite in an explosive atmosphere. The ignition temperature is one of the key factors used to classify the substance and determine the appropriate equipment and protective systems to be used in a potentially explosive environment.

ATEX Directive defines the ignition temperature as the lowest temperature at which a gas or dust will ignite in air, in the presence of an ignition source. The ignition temperature of a substance is dependent on its physical and chemical properties, and it can vary depending on the specific gas or dust, its concentration, and the conditions in which it is present.

For example, the ignition temperature of methane (CH4) is around 593°F (312°C) while the ignition temperature of dusts like coal dust is around 392°F (200°C).

It is important to note that the ignition temperature of a substance is different from the auto-ignition temperature (the lowest temperature at which a gas or dust will ignite without an external ignition source) or the flashpoint (the lowest temperature at which a liquid gives off vapor in sufficient concentration to ignite)

What Are The Protection Concepts?

The protection concepts are methods and approaches that are used by manufacturers to minimize the likelihood of explosive risks.

What is ATEX Zones?

In simple terms, ATEX Zones are dangerous areas classified based on environments and different levels of danger. The protection concepts and ATEX Zones must match the current market standards.

Classification of ATEX Zones

he ATEX Directive uses a classification system to identify areas where there is a risk of explosion due to the presence of flammable gases, vapours, dusts, or powders. The classification system is based on the likelihood and duration of the presence of an explosive atmosphere.

Zone 0: An area where an explosive atmosphere is present continuously or for long periods of time. Equipment used in this zone must be of explosion-proof or intrinsic safety design, and personnel must be trained in the safe use of the equipment.

Zone 1: An area where an explosive atmosphere is likely to occur in normal operation. Equipment used in this zone must be of flame-proof or other protective design, and personnel must be trained in the safe use of the equipment.

Zone 2: An area where an explosive atmosphere is not likely to occur in normal operation, and if it does occur, it will exist only for a short period. Equipment used in this zone must be designed to limit the effects of an explosion, and personnel must be trained in the safe use of the equipment.

Zone 20, 21 and 22 is a similar system for dust explosion classification. Zone 20 is an area where explosive dust atmosphere is present permanently, Zone 21 is an area where explosive dust atmosphere is likely to occur occasionally, and Zone 22 is an area where explosive dust atmosphere is not likely to occur.

The Zone 2 Negligible extent (NE) is a classification of hazardous areas under DSEAR, similar to the Zone 2 classification under the ATEX Directive, where an explosive atmosphere is not likely to occur in normal operation, and if it does occur, it will exist only for a short period.

However, there is a slight difference in the definition of Zone 2 NE, it is defined as an area where the likelihood of an explosive atmosphere arising is extremely low and, if it does arise, it will exist only over a noticeably short period. And the likelihood of an explosive atmosphere arising is so low that it can be considered as not being present at all.

Therefore, the Zone 2 Negligible extent (NE) classification is for areas where the likelihood of an explosive atmosphere arising is extremely low and equipment does not require specific protection but must be of appropriate design and construction, and personnel must be trained in the safe use of the equipment.

What is ATEX Approval?

ATEX Approval is the process of certifying that equipment and protective systems used in potentially explosive environments meet the requirements of the ATEX Directive.

The ATEX Directive is a set of regulations established by the European Union to ensure the safe use of equipment in areas where there is a risk of explosion due to the presence of flammable gases, vapours, dusts, or powders.

There are 2 European Directives for the control of explosive atmospheres –

ATEX Workplace Directive” or “ATEX 153”, also known as Directive 1999/92/EC
ATEX Equipment Directive or “ATEX 114”, also known as Directive 2014/34/EU

The ATEX Approval process involves testing equipment to ensure that it is designed, constructed, and tested in accordance with the ATEX Directive requirements. The testing is usually carried out by a notified body, which is an organization that has been designated by the EU to carry out conformity assessment procedures for the ATEX Directive.

ATEX Approval is mandatory for equipment that is intended for use in potentially explosive environments, such as those found in oil and gas production, chemical manufacturing, and other industries. The ATEX Approval process applies to all equipment, including electrical and non-electrical equipment, and protective systems.

It is important to note that the ATEX Approval only applies to equipment that is intended for use within the European Union and it must be regularly reviewed and renewed.

What is Intrinsically Safe?

Intrinsically safe is a type of equipment design that is used in potentially explosive environments to prevent the ignition of flammable gases, vapours, dusts, or powders. The intrinsic safety concept is based on the principle of limiting the energy available for ignition to a level below that which is required to ignite the substance present in the environment.

Intrinsically safe equipment is designed to prevent the release of sufficient electrical or thermal energy to cause ignition of the surrounding flammable atmosphere. This is achieved by using low power and low energy devices and limiting the amount of electrical and thermal energy that can be released in the event of a malfunction.

IP rating, also known as “Ingress Protection “, rating, is a standard used to measure the level of protection provided by enclosures for electrical equipment against the ingress of solid objects, dust, and water. The IP rating is represented by the letters “IP” followed by two digits. The first digit indicates the level of protection against solid objects and the second digit indicates the level of protection against water.

IP rating, also known as “Ingress Protection “, rating, is a standard used to measure the level of protection provided by enclosures for electrical equipment against the intrusion of solid objects, dust, and moisture. The IP rating system is defined in the International Electrotechnical Commission (IEC) standard 60529, and it is used in many countries, including the United Kingdom.

The IP rating system consists of two digits, the first digit indicating the level of protection against solid objects and the second digit indicating the level of protection against water.

The types of IP ratings in the UK are as follows:

The first digit (protection against solid objects): ranges from 0 to 6.

0: no protection
1: protection against solid objects larger than 50mm (e.g., hands)
2: protection against solid objects larger than 12mm (e.g., fingers)
3: protection against solid objects larger than 2.5mm (e.g., tools)
4: protection against solid objects larger than 1mm (e.g., wires)
5: dust protected (limited ingress of dust)
6: dust tight (no ingress of dust)

The second digit (protection against water): ranges from 0 to 8.

0: no protection
1: protection against dripping water (e.g., vertically falling drops)
2: protection against dripping water when tilted up to 15°
3: protection against spraying water (e.g., spray from any direction)
4: protection against splashing water (e.g., splashing water from any direction)
5: protection against water jets (e.g., water projected in jets from any direction)
6: protection against strong water jets (e.g., heavy seas)
7: protection against immersion up to 1 meter
8: protection against immersion beyond 1 meter

It is important to note that IP rating is not a substitute for other safety measures, such as explosion-proof enclosures and ventilation systems, which are required for equipment used in potentially explosive environments.

What is ATEX Certification?

ATEX Certification is the process of certifying that equipment and protective systems used in potentially explosive environments meet the requirements of the ATEX Directive. ATEX Directive is a set of regulations established by the European Union to ensure the safe use of equipment in areas where there is a risk of explosion due to the presence of flammable gases, vapours, dusts, or powders.

ATEX Certification involves testing equipment to ensure that it is designed, constructed, and tested in accordance with the ATEX Directive requirements. The testing is usually carried out by a notified body, which is an organization that has been designated by the European Union to carry out conformity assessment procedures for the ATEX Directive.

Once the equipment has been tested and found to be compliant with the ATEX Directive, it is issued with an ATEX certificate, which is a document that confirms that the equipment has been approved for use in potentially explosive environments. The certificate usually includes details such as the equipment’s type, model, and serial number, as well as the zone for which it is approved.

It is important to note that ATEX Certification is mandatory for equipment that is intended for use in potentially explosive environments, such as those found in oil and gas production, chemical manufacturing, and other industries. The ATEX Certification process applies to all equipment, including electrical and non-electrical equipment, and protective systems.

What Is ATEX Certified Equipment?

ATEX certified equipment must be designed, constructed, and tested in accordance with the ATEX Directive requirements, which include specific requirements for the materials, design, construction, and testing of equipment and protective systems.

The equipment must also be suitable for the specific type of explosive atmosphere it will be used in, whether it is a gas or dust atmosphere and the temperature class it falls in.

Examples of ATEX certified equipment include explosion-proof electrical equipment, intrinsically safe equipment, flameproof equipment, and explosion suppression systems.

It is important to note that the ATEX certification only applies to equipment that is intended for use within the European Union, it must be regularly reviewed and renewed. And it is the responsibility of the manufacturer or supplier to ensure that the equipment they provide is compliant with the ATEX Directive and that it is certified by a notified body.

What Is a Correlation Between EN 60079 and ATEX Certification?

The EN 60079 is a series of standards to test electrical equipment and assemblies that pose an ignition risk in explosive atmospheres. Each standard relates to a specific protection concept.

Do all equipment and material in ATEX Zones need to be ATEX Certified?

ATEX certification requirements depend on the category of equipment and its intended use in a particular zone. If a product itself cannot cause a spark or discharge, it cannot be considered a risk. So, in short, if a product has no ignition source, it cannot be ATEX certified.

Do I need to Certify Non-electrical equipment for use in an Explosive Atmosphere? If Yes, How?

If non-electrical equipment poses an ignition risk, it needs to be certified with ATEX Directives.

This equipment includes a motor, gear, units, air-powered drills, turbine assemblies, valves and rollers.

All these non-ignition equipment refer to standard EN 80079-36:2016 and EN 80079-37:2016.

It is advisable to design non-electrical products aligning with the standards that avoid serious difficulties.

How to Certify an ATEX product that you have not manufactured?

If you have not manufactured a product, it is important to know if the product material has been altered in the design process. Moreover, you may need to perform an amount of additional testing. Generally, certifying a product bought from another manufacturer/company or country is quite difficult if you don’t have a close working relationship with them.

When Is ATEX Certification Required?

ATEX certification is required for equipment that is intended for use in potentially explosive environments, such as those found in oil and gas production, chemical manufacturing, and other industries where flammable gases, vapours, dusts, or powders are present.

According to the ATEX Directive, equipment intended for use in potentially explosive environments must be designed, constructed, and tested in accordance with the ATEX Directive requirements and must be suitable for the specific type of explosive atmosphere it will be used in, whether it is a gas or dust atmosphere and the temperature class it falls in.

ATEX certification is mandatory for all equipment intended for use in potentially explosive environments, including electrical and non-electrical equipment, as well as protective systems. This includes equipment such as lighting fixtures, motors, generators, control systems, and ventilation systems.

It is important to note that ATEX certification is not just a one-time process, it must be regularly reviewed and renewed to ensure that the equipment remains compliant with the ATEX Directive requirements. And it is the responsibility of the manufacturer or supplier to ensure that the equipment they provide is compliant with the ATEX Directive and that it is certified by a notified body.

In summary, ATEX certification is required for equipment that is intended for use in potentially explosive environments where flammable gases, vapours, dusts, or powders are present, this includes electrical and non-electrical equipment, as well as protective systems, and it must be regularly reviewed and renewed to ensure compliance.

What is ATEX Rating?

ATEX rating, also known as an “ATEX Equipment Category”, is a classification system used to identify the level of protection provided by equipment used in potentially explosive environments. The ATEX rating system is defined in the ATEX Directive, which is a set of regulations established by the European Union to ensure the safe use of equipment in areas where there is a risk of explosion due to the presence of flammable gases, vapours, dusts, or powders.

The ATEX rating system is based on the likelihood and duration of the presence of an explosive atmosphere and is divided into three categories as shown in the table below:

The ATEX rating system applies to all equipment intended for use in potentially explosive environments, including electrical and non-electrical equipment, as well as protective systems.

It is important to note that the ATEX rating of equipment must be determined by a qualified person, taking into account the specific characteristics of the location and the type of activity being carried out.

It is important to note that the ATEX rating is different from the ATEX zones (0,1,2) which classify the hazardous areas based on the likelihood and duration of the presence of an explosive atmosphere. The ATEX rating classifies the equipment according to the level of protection required, while the ATEX zones classify the areas where the equipment will be used.

How Often Should ATEX Equipment Be Inspected?

According to the ATEX Directive, equipment intended for use in potentially explosive environments must be inspected and maintained on a regular basis to ensure that it remains compliant with the ATEX Directive requirements and that it continues to function safely.

The frequency of inspections for ATEX equipment depends on the type of equipment and the level of risk associated with its use. For example, equipment that is subject to wear and tear, such as motors and pumps, may require more frequent inspections than equipment that is not subject to wear and tear, such as lighting fixtures.

The frequency of inspections should be determined by a qualified person, taking into account the specific characteristics of the location, the type of activity being carried out, and the level of risk associated with the use of the equipment.

As a general guideline, it is recommended that ATEX equipment should be inspected at least once a year, or more frequently, if necessary, to ensure that it remains compliant with the ATEX Directive requirements and that it continues to function safely.

It is also important to note that any defects or issues that are identified during an inspection should be promptly repaired or corrected to ensure the continued safe operation of the equipment. And It is the responsibility of the manufacturer or supplier to ensure that the equipment they provide is compliant with the ATEX Directive and that it is certified by a notified body.

Is ATEX a Legal Requirement?

Yes, ATEX is a legal requirement in the European Union. The ATEX Directive (94/9/EC) is a set of regulations established by the European Union to ensure the safe use of equipment in areas where there is a risk of explosion due to the presence of flammable gases, vapours, dusts, or powders.

The ATEX Directive applies to equipment intended for use in potentially explosive environments, including electrical and non-electrical equipment, as well as protective systems. It sets out specific requirements for the design, construction, and testing of equipment and protective systems used in these environments, as well as the procedures for the approval and certification of equipment.

It is the responsibility of the manufacturer or supplier to ensure that the equipment they provide is compliant with the ATEX Directive and that it is certified by a notified body. It is also the responsibility of the users of the equipment to ensure that it is used in accordance with the ATEX Directive requirements.

In the UK, the ATEX Directive is implemented through the Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) 2002. The DSEAR regulations require employers to identify explosive atmospheres and to protect employees from the risks of fire and explosion.

In summary, ATEX is a legal requirement in the European Union, it applies to equipment intended for use in potentially explosive environments and it sets out specific requirements for the design, construction, and testing of equipment and protective systems used in these environments. Employers in the EU and UK must comply with the ATEX regulations to protect employees from the risks of fire and explosion.

How Much Do ATEX Inspections Cost?

The cost of ATEX inspections can vary depending on several factors such as the type of equipment being inspected, the location, the level of risk associated with its use, and the type of inspection (e.g., initial inspection, annual inspection, etc.). The cost of inspections can also vary depending on the company or organization conducting the inspection.

A rough estimate of the cost of ATEX inspections can range from a few hundred to several thousand pounds. For example, an initial inspection for a small piece of equipment might cost around £500, while an annual inspection for a large piece of equipment could cost £2000 or more.

It is important to note that the cost of inspections should not be the only factor considered when determining the frequency of inspections. The safety and compliance of the equipment should be the primary concern, and inspections should be scheduled based on the level of risk associated with the use of the equipment and the specific characteristics of the location,

It is recommended to contact several inspection companies and ask for a quote for the specific equipment and location to have a better idea of the cost of the inspection.

It is also worth noting that the cost of inspections is often a small fraction of the overall cost of maintaining and operating equipment, and regular inspections can help to identify potential issues before they lead to costly repairs or downtime.

Is ATEX Essential for Hazardous Area Operations?

Yes, ATEX regulations are essential for hazardous area operations. The ATEX Directive (94/9/EC) is a set of regulations established by the European Union to ensure the safe use of equipment in areas where there is a risk of explosion due to the presence of flammable gases, vapours, dusts, or powders.

ATEX regulations set out specific requirements for the design, construction, and testing of equipment and protective systems used in potentially explosive environments, including electrical and non-electrical equipment, as well as protective systems. They also establish procedures for the approval and certification of equipment.

By ensuring that equipment and protective systems used in hazardous areas are compliant with the ATEX regulations, it reduces the risk of fire and explosion, which can have severe consequences for both people and the environment.

ATEX regulations also require employers to identify explosive atmospheres and to protect employees from the risks of fire and explosion. This helps to ensure that employees are working in a safe environment, which is essential for their well-being and productivity.

In summary, ATEX regulations are essential for hazardous area operations as they ensure that equipment and protective systems used in potentially explosive environments are designed, constructed, and tested to meet specific safety standards, which helps to reduce the risk of fire and explosion, and protect employees from the risks of working in hazardous areas.

What do Businesses Need to Know About ATEX?

If you are a product manufacturer, it is important to be familiar with the relevant standards of ATEX that support you in avoiding any failures when it comes to testing later in the process.

It is important to have an “Ex” Logo to sell your product anywhere in Europe without any further concerns about potential risks.

What do we need to do next?

Orbis Environmental and Safety is one of the most well-known and reliable Health and Safety Consultants in the U.K.

The first step is to contact us. Either call the head office line where one of the consultants can answer your questions (we do not use salespeople so you will ONLY talk to a qualified person).

We will then discuss the project in detail and agree a project delivery timescale and take things from there. We would typically lead on these projects to give you confidence things are progressing.

It is advisable for employers to choose a competent health and safety service provider and to ensure that assessments are carried out aligning with the latest laws and regulations of health and safety standards.

To know more or chat to a consultant, pop an email over to us at [email protected] or call us on – 01656 470044. We will be in touch within 1 hour.

If it is urgent, please email our senior consultant Ryan Lloyd-Davies (CMIOSH) on [email protected]

Guide to ATEX Regulations, Certification, Rating & Zone