Introduction : The importance of ATEX modernization
The existing industrial installations in the aerospace and energy sectors in France are subject to increasingly strict safety and efficiency requirements. ATEX standards, regulated by Directive 2014/34/UE, impose rigorous controls on electrical equipment used in explosion‑risk zones. The modernization of these installations, often called retrofitting, has become a necessity to meet European regulations, improve energy efficiency, and reduce maintenance costs.
Evaluation of existing systems before modernization
Before any renovation, it is essential to analyze the existing systems. This evaluation must cover several technical and regulatory criteria. The following table summarizes the key parameters to examine:
| Evaluation criterion | Standard applicable | Minimum requirement | Observation |
|---|---|---|---|
| Explosion class (zone) | EN 50038 | Zone 1 or 2 | To be checked via a fire and explosion analysis. |
| Type of installation | EN 60079-1 | Zone 1 or 2 | Identify the risk zones. |
| Protection Class | EN 60079-7 | Exd or Exe | Compliance with ATEX standard. |
| Historical maintenance | EN 50153 | Complete documentation | Maintenance history present. |
| Maintenance Costs | ISO 55000 | Maintenance Hourly Costs | Evaluate annual maintenance costs. |
Modern Alternatives : Comparison of Old and Modern Technologies
Replacing old ATEX components with modern systems offers significant advantages in terms of safety and efficiency. The recommended replacement component is Allen Bradley 1485C-P1-A300, compliant with the standards ATEX 2014/34/UE and EN 60079-1. The following table compares the performance of the two technologies:
| Parameter | Old component | Allen Bradley 1485C-P1-A300 |
|---|---|---|
| Protection Class | Exd | Exe |
| ATEX Compliance | Yes | Yes |
| Energy efficiency | 85 % | 92 % |
| MTBF (hours) | 5 000 | 10 000 |
| Purchase Cost (€) | 450 | 700 |
| Annual maintenance cost (€) | 300 | 150 |
Return on Investment (ROI) calculation
The ROI of an ATEX modernization is calculated based on energy savings, reduction in maintenance costs, and decrease in downtime. Considering the following data:
- Electricity cost: 0,15 €/kWh
- Maintenance cost per hour: 60 €/h
- Annual average downtime : 150 h
- Energy reduction: 10 %
The calculation proceeds as follows:
- Annual energy reduction: 10 % × 5 000 kWh = 500 kWh
- Energy saving: 500 kWh × 0,15 €/kWh = 75 €
- Downtime reduction: 10 % × 150 h = 15 h
- Maintenance cost saving: 15 h × 60 €/h = 900 €
- Total annual saving: 75 € + 900 € = 975 €
- Initial investment : 700 €
- Payback period : 700 € / 975 € ≈ 0,72 année
This analysis confirms that the ROI is positive from the first year.
Phase Implementation Plan
The modernization of an ATEX installation must be carried out in phases to minimize production disruptions. The following plan is recommended:
- Planning : Installation assessment, identification of hazardous areas, and validation of replacement components.
- Procurement : Ordering of modern components via UNITEC-D E-Catalog, complying with ATEX, CE and NF standards.
- Installation : Replacement of old components with new ones, following safety and compliance procedures.
- Commissioning : Functional tests, performance verification, and validation by an ATEX expert.
This approach allows maintaining production continuity while ensuring regulatory compliance.
Technical Challenges and Solutions
The main difficulties during an ATEX retrofitting include:
- Component Compatibility : Some old components are no longer available. Solution : Use modern certified ATEX components available via UNITEC-D.
- Integration into existing installation : Dimensions and interfaces may vary. Solution : Adapt components via adapters or minor modifications.
- Transition Costs : Replacement costs can be high. Solution: Use certified used components or modern used components via UNITEC-D.
These solutions reduce total costs while ensuring compliance with standards.
Case Study: Before/After
An aerospace plant modernized its ATEX systems by replacing the old components with Allen Bradley 1485C-P1-A300. The results are as follows:
- Before : MTBF of 5 000 hours, energy efficiency of 85 %, annual downtime of 150 hours.
- After : MTBF of 10 000 hours, energy efficiency of 92 %, annual downtime of 100 hours.
This modernization allowed an annual saving of €975, a 50 % gain in MTBF and a 33 % reduction in downtime.
Commissioning procedures and acceptance criteria
The commissioning process must include the following steps:
- Compliance Tests : Compliance check to ATEX, CE, and NF standards.
- Performance Tests : Measurement of energy efficiency, MTBF, and reliability.
- Expert validation : An industrial safety expert must validate the results.
The acceptance criteria include compliance with standards, an energy efficiency greater than 90 %, and an MTBF greater than 10 000 hours.
Conclusion and Call to Action
Modernization of ATEX installations is a necessity for companies in the aerospace and energy sectors in France. The gains in efficiency, safety, and compliance fully justify the investment. UNITEC-D E-Catalog offers a complete range of ATEX certified components, CE, NF and ATEX, ideal for retrofitting projects. To discover our solutions, visit UNITEC-D E-Catalog.
References
- Directive 2014/34/EU – ATEX Standards
- EN 50038 – Classification of explosive hazard areas
- EN 60079-1 – Electrical Equipment Safety in Explosive Atmospheres
- EN 60079-7 – Protection by shielding and by sealing
- ISO 55000 – Asset Management
- UNITEC-D – ATEX Component Migration Guide
