Introduction

The safe operation of industrial facilities, especially those working with flammable gases, vapors, dusts or flammable liquids, is critically important. Explosive atmospheres pose a significant risk to personnel, equipment and the environment. ATEX directives (from the French "Atmosphères Explosibles") is a fundamental regulatory act of the European Union aimed at preventing explosions and protecting the health and safety of workers. In Ukraine, these requirements are implemented through national standards of the DSTU EN series. Ensuring compliance of all components, in particular spare parts, with these standards is not only a legal requirement, but also a basic prerequisite for uninterrupted and safe production.

Scope and obligation

The ATEX directives consist of two main parts: Directive 2014/34/EU covers equipment and protective systems intended for use in potentially explosive atmospheres, while Directive 1999/92/EC sets minimum requirements to improve the safety and health of workers exposed to the risk of exposure to explosive atmospheres. These standards are mandatory for all enterprises where the formation of explosive gas, vapor or dust mixtures with air is possible.

ATEX compliance applies to a wide range of industries, including oil and gas, chemical, pharmaceutical, food, woodworking, mining, and energy. The equipment covered by these directives includes electrical and non-electrical devices: electric motors, pumps, valves, sensors, control panels, lighting devices, cables, seals, bearings and many other components that can be a source of ignition or operate in an explosive area. Compliance is the responsibility of business owners, operators, heads of maintenance departments and purchasing departments.

Basic requirements

Compliance with ATEX requirements is based on a comprehensive risk assessment and subsequent classification of potentially explosive areas. This classification defines the type and level of protection required for equipment and components. Below is a summary table of the main liabilities:

The key requirements are:

• Risk assessment and zone classification: Detailed analysis of potential ignition sources and their respective classification according to DSTU EN 60079-10-1 (gases) and DSTU EN 60079-10-2 (dusts).
• Equipment selection: Use only those equipment and spare parts that are certified for the respective zone and category.
• Documentation: Availability of declaration of conformity, ATEX certificates, operating and maintenance instructions.
• Marking: Each component must have a clear ATEX marking (eg CE Ex II 2G Ex db IIC T6 Gb).
• Personnel training: Regular training of all personnel working in explosive areas on risks and safety procedures.
• Maintenance and Inspections: Develop and implement routine inspection and maintenance programs to ensure continued equipment compliance.

Impact on maintenance and repair (MRO) operations

Implementing and maintaining ATEX compliance has a significant impact on all aspects of MRO. This requires a review of existing practices and the introduction of new, more stringent procedures.

Maintenance

Maintenance procedures must be adapted to ATEX requirements. This includes:

• Use of certified tools: All tools used in hazardous areas must be intrinsically safe and be marked accordingly.
• Specific procedures for "hot work": Work that generates heat, sparks or open flames (welding, cutting) requires a work permit and strict controls.
• Regular Inspections: Scheduled inspections of equipment for damage, corrosion, condition of seals and cables, and integrity of protective shells.
• Correct installation and repair: Any repair or replacement of components must be performed in accordance with the manufacturer's instructions and using only original or equivalent certified replacement parts.

Procurement

The purchasing department plays a key role in ensuring ATEX compliance:

• Purchase only certified spare parts: Every spare part intended for use in an explosive area must be accompanied by the appropriate ATEX certificate.
• Verification of suppliers: Cooperation only with reliable suppliers who can provide full documentation and guarantee product compliance.
• Checking documentation: Thorough checking of certificates, declarations of conformity and labeling before accepting the goods.

Documentation

Maintaining accurate and up-to-date documentation is critical to demonstrating compliance:

• Retention of ATEX certificates:Retention of all certificates for equipment and spare parts.
• Risk assessments: Keeping records of zone classification and risk assessment results.
• Inspection logs: Keeping all logs of regular checks and maintenance.
• Maintenance logs: Record of all work performed, spare parts used, and equipment configuration changes.

Requirements for components

Each component used in potentially explosive atmospheres must be appropriately labeled and meet specific requirements. For example, Zone 1, where an explosive atmosphere is likely to be present, may require Category 2G equipment. Typical labeling includes:

• CE symbol: Certifies compliance with European standards.
• The symbol Ex: Indicates that the equipment is intended for use in potentially explosive atmospheres.
• Equipment group: Group I (for mines) or Group II (for surface installations). Most industrial enterprises use Group II.
• Equipment category: 1, 2 or 3 corresponding to zones 0/20, 1/21 or 2/22.
• Environment: G for gas/vapour, D for dust.
• Type of protection: For example, db (explosion-proof shell), ia (intrinsic safety), e (increased safety), t (dust protection) corresponding to DSTU series EN 60079.
• Gas/dust subgroup: For example, IIC for hydrogen/acetylene or IIB for ethylene.
• Temperature class: T1 (450°C) to T6 (85°C), indicating the maximum surface temperature. For example, an electric motor marked T4 cannot exceed 135°C.
• Equipment Protection Level (EPL): Ga, Gb, Gc (for gas) or Da, Db, Dc (for dust) indicating the level of protection against ignition.

For example, bearings for pumps operating in Zone 1 must be certified for non-electrical equipment in accordance with DSTU EN ISO 80079-36 and DSTU EN ISO 80079-37, which ensures that there is no risk of sparking or heating above the temperature class. Seals used in valves for aggressive chemical environments in Zone 0 must not only be chemically resistant, but also must not allow leaks that could create an explosive atmosphere and have an appropriate EPL.

A practical compliance checklist for the maintenance manager

1. Is there an up-to-date classification of explosive zones at your company? (Last check: 2025)
2. Are all installed electrical and non-electrical components clearly ATEX marked?
3. Are ATEX certificates and declarations of conformity available and current for all equipment?
4. Are only spare parts with the appropriate ATEX certification for the specific zone used?
5. Is compliance of certificates checked when purchasing each batch of spare parts?
6. Are special maintenance procedures developed and implemented for ATEX areas?
7. Are all tools used in hazardous areas intrinsically safe and certified?
8. Are personnel working in potentially explosive areas appropriately qualified and regularly trained? (Last certification: 2026)
9. Are there regular checks on the integrity of protective sheaths and cables?
10. Does the system of work permits for "hot" and other dangerous operations function?
11. Are the grounding and equipotential bonding systems working effectively?
12. Are all potential ignition sources (static electricity, hot surfaces, sparks) controlled?
13. Are repairs performed only by qualified personnel using certified components?
14. Is a complete maintenance log kept, including ATEX components replaced?
15. Are ventilation systems tested for their effectiveness in dispersing explosive mixtures?
16. Are there clear instructions on what to do in the event of equipment malfunctions in the ATEX zone?
17. Are all entrances to explosive areas controlled and restricted?
18. Are ATEX requirements taken into account when designing new facilities or upgrading existing ones?
19. Do non-electrical components (for example, fans, reducers) meet the requirements of DSTU EN ISO 80079-36 and DSTU EN ISO 80079-37?
20. Is there an internal audit system to verify ATEX compliance?

Typical inconsistency problems

Auditors often identify a number of typical violations that can lead to serious consequences:

• Incorrect zone classification: Underclassification or outdated classification, resulting in the use of inappropriate equipment.
• Using non-certified spare parts: Purchasing and installing components without proper ATEX certification or with incorrect labeling.
• Improper installation or repair: Failure to follow the manufacturer's instructions during installation or repair, which may violate the protective properties of the equipment.
• Lack or outdated documentation: Incomplete or missing certificates, declarations, inspection protocols.
• Insufficient staff training: Lack of understanding of risks and safety procedures among employees.
• Lack of regular inspections: Neglecting routine inspections resulting in undetected damage or wear and tear.
• Modifications without re-evaluation: Making changes to equipment without re-assessing the risks and confirming ATEX compliance.

Penalties and liability

Failure to comply with ATEX requirements can result in significant legal, financial and reputational consequences. In Ukraine, according to the Code of Ukraine on Administrative Offenses and the Criminal Code of Ukraine, violation of industrial safety rules related to the operation of explosive objects is punishable by:

• Administrative fines: For company officials - from 500 to 1,000 tax-free minimum incomes of citizens (from 8,500 to 17,000 hryvnias) for the first violation. For repeated violations within a year, fines increase.
• Suspension of activity: State supervision bodies can temporarily or completely suspend the activity of workshops, districts or the entire enterprise until the identified violations are eliminated.
• Criminal liability: In case of serious consequences (industrial injury, death, large-scale destruction), the responsible persons (chief engineer, production manager, occupational safety engineer) may be held criminally liable with imprisonment for a term of up to 8 years (Articles 271, 272 of the Criminal Code).
• Cancellation of insurance policies: Most insurance companies will cancel coverage if the incident occurred due to non-compliance with established safety standards.
• Financial losses: Direct expenses for elimination of the consequences of the accident (recovery of equipment, cleaning of the territory), compensation to the victims, losses from the stoppage of production. For example, the cost of restoring one industrial tank after an explosion can reach 500,000 euros, excluding the costs of environmental remediation.
• Reputational damage: Loss of trust of clients, partners and negative impact on the company's image.

Conclusion

Compliance with ATEX directives is an integral part of risk management in industrial explosive environments. It is an integrated approach covering design, procurement, installation, operation and maintenance. The use of certified spare parts is one of the fundamental pillars of this system. Failure to comply with these requirements not only creates security risks, but also carries significant legal and financial consequences.

UNITEC-D GmbH is a reliable supplier of certified components for use in hazardous areas, ensuring that every part supplied meets the highest safety standards. We offer a wide range of ATEX compliant products including bearings, seals, actuators and other equipment required for your production.

For detailed information on certified components and ensuring ATEX compliance, visit the UNITEC-D E-Catalog.

Sources

• Directive 2014/34/EU of the European Parliament and of the Council of February 26, 2014 on the harmonization of the laws of the Member States regarding equipment and protective systems intended for use in potentially explosive atmospheres.
• Directive 1999/92/EC of the European Parliament and the Council of December 16, 1999 on minimum requirements for improving the safety and health of workers exposed to the risk of exposure to explosive environments.
• DSTU EN 60079 (series of standards): Explosive atmospheres.
• DSTU EN ISO 80079-36:2018. Explosive atmospheres. Part 36. Non-electrical equipment for potentially explosive atmospheres. Basic method and requirements (EN ISO 80079-36:2016, IDT).
• DSTU EN ISO 80079-37:2018. Explosive atmospheres. Part 37. Non-electrical equipment for potentially explosive atmospheres. Protection by structural safety "c", ignition source control "b" and liquid immersion "k" (EN ISO 80079-37:2016, IDT).
• Code of Ukraine on Administrative Offenses, Article 93. Violation of requirements of legislation on labor protection and industrial safety.
• Criminal Code of Ukraine, Article 271, 272. Violation of requirements of labor protection legislation.

1. Introduction

In industrial sectors where the presence of flammable gases, vapours, mists or combustible dusts creates a potential explosion hazard, ensuring absolute safety is a critical task. European Union Directive 2014/34/EU, known as ATEX (from the French ATmosphères EXplosibles), establishes mandatory requirements for equipment and protective systems intended for use in explosive environments. This applies not only to new equipment, but also to every spare part that functions in such conditions. Failure to comply with these requirements can lead to catastrophic consequences, from significant property damage to personal injury and death, as well as serious legal and reputational problems for the enterprise. This article examines in detail aspects of ATEX certification of spare parts, zone classification, equipment categories and marking, which is key to ensuring reliable and safe operation of production facilities in Ukraine in accordance with international and national standards, in particular DSTU EN 60079.

2. Scope of Application and Obligation

The ATEX 2014/34/EU Directive covers equipment and protective systems intended for use in potentially explosive atmospheres, as well as components that are essential for their safe operation. A key aspect is the classification of explosive zones:

• Zones for gases, vapors and mists (EN 60079-10-1):
  • Zone 0: A space in which an explosive gas atmosphere is present continuously or for long periods of time.
  • Zone 1: A space in which an explosive gas atmosphere is likely to occur during normal operation.
  • Zone 2: A space in which an explosive gas atmosphere is unlikely and, if it occurs, for a short period of time.
• Combustible Dust Zones (EN 60079-10-2):
  • Zone 20: A space in which an explosive dust atmosphere is present continuously or for long periods of time.
  • Zone 21: A space in which an explosive dust atmosphere is likely to occur during normal operation.
  • Zone 22: A space in which an explosive dust atmosphere is unlikely and, if it occurs, for a short period of time.

Mandatory ATEX compliance applies to manufacturers, importers, distributors and end users (operators) in all industries where there is a risk of explosion, including oil and gas, chemical, pharmaceutical, food, woodworking and others. Equipment is divided into groups and categories:

• Group I: Equipment for underground parts of mines, as well as surface installations of these mines, which may be exposed to the danger of methane explosion and/or combustible dust.
  • Category M1 (very high level of protection)
  • Category M2 (high level of protection)
• Group II: Equipment for use in other locations that may be at risk of explosive atmospheres.
  • Category 1 (very high level of protection, for Zone 0/20)
  • Category 2 (high level of protection, for Zone 1/21)
  • Category 3 (normal level of protection, for Zone 2/22)

3. Key Requirements and Markings

To ensure ATEX compliance, equipment and components must meet the Essential Health and Safety Requirements (EHSRs) set out in Annex II to Directive 2014/34/EU. Conformity assessment procedures (modules) depend on the equipment group and category. After successfully passing the conformity assessment, the equipment is marked with the CE mark and a special Ex marking.

Example of ATEX Marking:

CE 0123 Ex II 2G Ex db IIC T6 Gb 

Decoding:

• CE: Meets EU requirements.
• 0123: Notified body number (if applicable).
• Ex: Explosion protection symbol.
• II: Group of equipment (for ground industry).
• 2: Equipment category (for Zone 1 for gas or Zone 21 for dust).
• G: Type of explosive atmosphere (Gas – gas, D – Dust – dust).
• Ex db: Type of protection (d – explosion-proof enclosure according to EN 60079-1).
• IIC: Gas subgroup (IIC – acetylene, hydrogen; IIB – ethylene; IIA – propane).
• T6: Temperature class (T6 – maximum surface temperature 85°C).
• Gb: Equipment Protection Level (EPL - Equipment Protection Level): Ga (very high), Gb (high), Gc (enhanced).

Correspondence Table of Zones and Categories

4. Impact on MRO Operations

Implementing and maintaining ATEX compliance has a significant impact on maintenance, repair and operation (MRO) operations in industrial plants. This requires a comprehensive approach and integration of ATEX requirements into all relevant processes:

• Procurement: Procurement departments must ensure that all spare parts intended for use in potentially explosive areas have the appropriate ATEX certification. Documentation such as certificates of conformity, technical data sheets and declarations from manufacturers must be carefully checked. Suppliers like UNITEC-D are key partners in providing access to certified components.
• Maintenance Planning: MRO procedures in explosive areas must be adapted to minimize risks. This includes the development and implementation of a permit-to-work system, detailed instructions for dismantling, installing and repairing equipment taking into account explosion protection.
• Personnel Training: All personnel involved in MRO in potentially explosive areas, from mechanics to engineers and supervisors, must undergo specialized ATEX training. Training should include an understanding of zone classification, equipment marking, safe work procedures, and the specifics of using explosion-proof tools.
• Inventory Management: ATEX certified spare parts must be stored separately to prevent accidental use in inappropriate areas or mix-up with non-certified counterparts. Clear identification and accounting system are mandatory.
• Documentation: Keeping a complete and up-to-date register of ATEX certificates, maintenance reports, inspection reports and risk assessments is fundamental. This ensures transparency and enables prompt response to any audits or incidents.
• Risk Assessment: Regular review and updating of the Explosion Protection Document (EPD) is vital. Any change in the process, equipment or environment should trigger a re-evaluation of the explosion risks.

5. Requirements for Components

Even the slightest malfunction or the use of an inappropriate spare part in an explosive zone can cause a disaster. Therefore, special requirements are placed on a wide range of components:

• Bearings: Under ATEX conditions, bearings must not generate sparks or excessive heat. Characteristics such as seal type, cage material and lubricant are important. Some applications may require bearings with ceramic elements or special antistatic properties. The temperature class of the equipment (for example, T4, where the maximum surface temperature is 135°C) is decisive for the selection of bearings that do not overheat.
• Electric Motors and Drives: They are one of the most common sources of ignition. Appropriate types of protection are required, such as explosion-proof enclosure (Ex d according to EN 60079-1), increased safety (Ex e according to EN 60079-7), intrinsically safe electric circuit (Ex i according to EN 60079-11). The engine surface temperature should not exceed the temperature class of the atmosphere.
• Pumps and Compressors: Tightness, construction materials and sealing systems are critical. It is necessary to prevent leakage and accumulation of static electricity. Pumps for flammable liquids must meet equipment requirements for gas/vapor areas.
• Valves and Actuators: Can be certified as intrinsically safe (Ex i) for control signals or have explosion-proof housings for electromagnetic actuators (Ex d). Sealing materials must be chemically resistant to the pumped medium and have an appropriate temperature range.
• Sensors and Encoders: Intrinsically safe sensors (Ex i) are mainly used, limiting the energy of the electric circuit to a level that cannot cause ignition. Installation requires the use of appropriate intrinsically safe barriers.
• Cables and Cable Glands: Must be certified for use in potentially explosive atmospheres, provide explosion protection integrity (e.g. tightness of cable glands) and have appropriate mechanical and thermal characteristics.

Replacing even a seemingly insignificant component, such as an oil seal or a gasket, with an uncertified counterpart can completely invalidate the explosion protection of the entire assembly, creating a hidden but deadly risk.

6. Compliance Checklist for Maintenance Managers

This practical checklist will help you ensure the proper level of ATEX compliance at your facility:

1. Check the relevance of the classification of explosive zones at your facility according to EN 60079-10-1/2.
2. Check the ATEX marking on all equipment with its installation location and zone classification.
3. Ensure that all spare parts for Ex equipment have the appropriate ATEX certification and proper marking (CE, Ex, category, temperature class, EPL).
4. Keep a register of all certificates of conformity and declarations from manufacturers for Ex-equipment and spare parts.
5. Check the manufacturer's instructions for installation, operation and maintenance of Ex equipment.
6. Implement and strictly enforce a permit-to-work system for all work in explosive areas.
7. Have Ex-equipment regularly inspected by qualified personnel in accordance with EN 60079-17 (Inspection and Maintenance).
8. Organize periodic ATEX training for all personnel working in explosive areas.
9. Document all maintenance, repair and modification of Ex equipment.
10. Ensure that outside contractors working in potentially explosive atmospheres are properly qualified and certified.
11. Check the reliability of grounding and equipotential bonding for all Ex-equipment.
12. Use antistatic materials and clothing to prevent the build-up of static electricity.
13. Use only certified non-sparking tools when working in Ex-zones.
14. Develop a clear procedure for identifying and disposing of non-conforming or damaged Ex-components.
15. Regularly update the Explosion Protection Document (EPD) to reflect changes in processes or equipment.
16. Ensure proper storage of ATEX-certified spare parts separately from others.
17. When repairing, use only original or reference certified spare parts.
18. Root out unauthorized modifications or workarounds in Ex equipment.
19. Implement a system for monitoring the service life of critical Ex-components.
20. Check the presence and functionality of emergency systems, such as fire extinguishing and emergency shutdown systems.

7. Typical Problems of Inconsistency

During audits and inspections, control bodies often identify the following typical problems of non-compliance with ATEX requirements:

• Using non-certified spare parts: The most common violation that can instantly invalidate the equipment's explosion protection.
• Incorrect interpretation of labeling: Misunderstanding or ignoring the values ​​of the Ex labeling, which leads to the installation of equipment of the wrong category in this zone.
• Insufficient or outdated documentation: Incomplete or outdated certificates, declarations, instructions and EPDs.
• Insufficient staff training: Workers do not know or understand ATEX requirements, safe work procedures and equipment limitations.
• Improper maintenance practices: Damage to explosion-proof enclosures during repairs, incorrect bolt tightening, leaking cable entries.
• Ignoring static electricity hazards: Failure to use grounding, antistatic clothing, or tools that could cause sparking.
• Unauthorized modifications: Making changes to Ex-equipment without proper evaluation and re-certification, which completely compromises its explosion-proof properties.
• No re-assessment of risks: Changes in the production process, raw materials or equipment layout are not accompanied by EPD updates and re-evaluation of explosive areas.

8. Penalties and Liability

Non-compliance with ATEX requirements in Ukraine can have significant legal and financial consequences. The responsibility system includes:

• Administrative Fines: Violations of labor protection and industrial safety legislation regulated by the Code of Ukraine on Administrative Offenses may impose significant fines on enterprises and responsible officials. Fines can vary from hundreds to thousands of tax-free minimum incomes of citizens, depending on the severity and frequency of the violation.
• Criminal Liability: In the event that the violation of ATEX requirements has led to serious consequences, such as accidents, injuries, explosions or death, company officials may be held criminally liable according to the Criminal Code of Ukraine (for example, Article 271 "Violation of the requirements of labor protection legislation", Article 272 "Violation of safety rules during the performance of work with increased risk"). This can include imprisonment for up to 10 years.
• Civil Liability: The company is responsible for compensation for damages caused by the explosion, including damage to property, damage to health and life of employees, as well as environmental damage. Compensation amounts can reach tens and hundreds of millions of hryvnias.
• Insurance Consequences: Insurance companies may deny coverage for insured events if it is proven that the explosion occurred due to ATEX non-compliance. This places all financial risks directly on the enterprise.
• Reputational Losses: Incidents related to explosions cause irreparable damage to a company's reputation, which can lead to a loss of trust from customers, partners and a drop in market value.

The UkrSEPRO national certification system also takes into account international requirements for explosion-proof equipment, adapting them to Ukrainian legislation.

9. Conclusion

Compliance with the requirements of the ATEX 2014/34/EU Directive and the corresponding standards of the EN 60079 series is not just a formal requirement, but a vital necessity for industrial enterprises operating in explosive environments. It is the foundation for creating a safe working environment, protecting personnel, preserving assets and ensuring the continuity of production processes. Investing in certified spare parts and strict adherence to MRO protocols with ATEX in mind is a cost-effective and strategically important decision to avoid colossal losses. UNITEC-D is a reliable partner supplying a wide range of certified components fully compliant with international safety standards. Ensure uncompromising security and compliance across your enterprise.

View our catalog of certified components at UNITEC-D E-Catalog.

10. Links

• Directive 2014/34/EU of the European Parliament and of the Council of February 26, 2014 on equipment and protective systems intended for use in potentially explosive atmospheres.
• The EN 60079 series of standards (eg EN 60079-0, EN 60079-1, EN 60079-7, EN 60079-11, EN 60079-17) - Explosive atmospheres.
• DSTU EN 60079 (relevant national adaptations of European standards).
• Relevant national standards and legislative acts of Ukraine on labor protection and explosion protection.