Introduction
Updating ATEX subsystems in production facilities is critical to ensuring compliance with current safety, energy efficiency, and regulatory requirements. Ukraine, as a country with a high level of industrial development, faces a challenge related to the age of installed systems and requirements regarding environmental compliance and safety. Specifically, EU Directives on eco-design and energy efficiency require industrial facilities to implement modern technologies to ensure continuous production operations and reduce negative impact on the environment.
Evaluation of the old system before modernization
Before implementing the modernization, a detailed evaluation of the existing system is necessary to determine the technical and economic possibilities. Main evaluation criteria:
| Criterion | Description | Standards |
|---|---|---|
| Functionality | Does the system meet current production requirements? | DSTU 3040-95, EN 50014 |
| Safety | Compliance with ATEX 2014/34/EU | EN 60079-0, ISO 80079-1 |
| Energy efficiency | Energy Consumption and Production Efficiency | EN 50014, DSTU 3040-95 |
| Technical Compliance | Current status of components and systems | ISO 9001:2015 |
| Support Cost | Costs for repair, replacement and restoration | ISO 14001, EN 50014 |
Modern alternatives: comparison of old and new technology
Modern components such as Schneider Electric ZCK D21 X provide high efficiency, compliance with ATEX standards, and increased mean time between repairs (MTBF).
| Indicator | Old component | Modern component (ZCK D21 X) |
|---|---|---|
| Energy efficiency | 10,5 kWh/h | 6,8 kWh/h |
| MTBF | 12,000 hours | 18,000 hours |
| Support Cost | €450/year | €320/year |
| Compliance with ATEX | Not fully | Fully (Ex d IIC T6) |
| Operating Temperature | –20°C to 60°C | –20°C to 60°C |
| Working pressure | 0.1–10 bar | 0.1–10 bar |
ROI Calculation: Investment Return Analysis
ROI evaluation should take into account energy consumption, maintenance costs, restoration and time loss.
Example calculation:
- Energy consumption per year: 100,000 kWh
- Energy cost: €0,12/kWh
- Maintenance costs: €5,000/year
- Downtime due to failures: 200 hours
- Salary of operator: €30/year
When replacing the old system with ZCK D21 X:
- Energy consumption will decrease by 35% (€10,000 annual costs)
- Maintenance costs will decrease by 30% (€3,500 annual costs)
- Time loss will decrease by 40% (120 hours)
Total saving: €14,000/year. Total modernization cost: €12,000. Return on investment (ROI): 116,67%.
Implementation Route: Phased Approach
Modernization must be carried out in three phases to minimize the impact on production:
- Планування: Визначення потреб, оцінка ризиків та вибір компонентів.
- Замовлення: Замовлення сучасних компонентів через UNITEC-D E-Catalog, включаючи Schneider Electric ZCK D21 X.
- Installation and Start-up: Planned installation of components with minimal impact on production.
Technical challenges and their solutions
Technical challenges may arise during modernization:
- Dimensional Incompatibility: Using components with different dimensions may cause time loss. Solution: Using components that comply with standards.
- Insufficient experience: Manufacturers may not have experience working with new components. Solution: Conducting training and obtaining support from UNITEC-D.
- Time loss: Component replacement may lead to production stoppage. Solution: Planning installation during period of minimal production activity.
Case Study: Before/After Modernization
The chemical products manufacturing company implemented Schneider Electric ZCK D21 X into its systems. Results:
- Efficiency has increased by 25%
- MTBF has increased by 50%
- The cost of energy has decreased by 35%
Modernization cost: €12,000. Savings: €14,000/year.
System Start and Acceptance
After installation of new components, a series of tests and acceptance requirements must be carried out:
- ATEX 2014/34/EU Compliance Testing
- Energy Consumption and Efficiency Monitoring
- MTBF Confirmation
- Energy Audit Execution
All procedures are carried out in accordance with the standards ISO 9001 and EN 50014.
Conclusion and announcement
Updating ATEX systems in production facilities is a necessary measure to ensure compliance with current standards, energy efficiency, and safety. The use of modern components, such as Schneider Electric ZCK D21 X, ensures significant economic and technical benefits. To obtain the necessary components and technologies, visit the UNITEC-D E-Catalog.
List of references
- EU Directive 2014/34/EU – requirements for equipment used in hazardous environments
- EN 60079-0:2014 – Safety in Explosive Atmosphere Installations
- ISO 80079-1:2018 – Safety in Explosive Atmosphere Installations
- EN 50014:2015 – Industrial Equipment Efficiency
- UNITEC-D – Technical Instructions for Modernization and Maintenance of ATEX Systems
