Introduction: Why the ATEX standard is important for the functioning of production

Among the various safety standards that determine the safety of industrial installations, the ATEX standard is of particular importance. This standard, adopted in the European Union, regulates the use of electrical equipment in hazardous areas where there is a risk of explosion due to the presence of open flames, vapors or dust. Ukraine, as a country with a developed industry, must comply with ATEX requirements to ensure the safety of workers and avoid unexpected explosions.

Scope of application: who must comply with ATEX requirements

The ATEX standard applies to industrial installations located in hazardous areas defined in accordance with DSTU 2158-2020, DSTU 2157-2020 and DSTU 2156-2020. These areas include workplaces where an explosion could occur due to the presence of open flames, dust, gas or vapors. ATEX requirements apply to electrical equipment used in these areas, including electric motors, gearboxes, pumps and other components.

Essential Requirements: Table of Key Responsibilities

Impact on MRO operations: changes in maintenance, procurement and documentation

The application of the ATEX standard significantly affects the work of MRO (Maintenance, Repair, Operations). The production, maintenance and repair of electrical equipment in hazardous areas must fulfill additional requirements for the use of products conforming to the standard. In these zones, restrictions are placed on the use of electrical equipment that does not meet ATEX requirements. To carry out maintenance in such areas, it is necessary to use special tools that meet the standards and to keep records of maintenance and repairs.

Component requirements: which spare parts must meet ATEX requirements

Spare parts used in hazardous areas must be certified according to ATEX requirements. This includes electric motors, gearboxes, pumps, fans, electric drives and other components. Requirements for the use of spare parts are determined by standards EN 60079-1:2014, EN 60079-7:2014, EN 60079-15:2014 and DSTU 2158-2020. Certification requires the performance of tests for explosiveness, compliance with the requirements of various categories and zones.

Conformity Check: A Practical Check for Maintenance Managers

1. Check whether the spare parts meet the ATEX standard.
2. Set the level of risk in the area of ​​use.
3. Choose a category according to the level of risk.
4. Check whether the component has a certificate of conformity.
5. Prepare compliance documentation.
6. Check for explosiveness.
7. Keep a log of the use of spare parts.
8. Update documentation on meeting ATEX requirements.
9. Carry out regular checks of electrical equipment.
10. Perform maintenance in accordance with ATEX requirements.
11. Keep maintenance and repair reports.
12. Conduct training for staff.
13. Perform a security audit at the enterprise.
14. Keep documentation on compliance with ATEX requirements.
15. Perform periodic compliance checks.
16. Perform explosive tests.
17. Keep a log of the use of spare parts.
18. Perform maintenance in accordance with ATEX requirements.
19. Keep maintenance and repair reports.
20. Conduct training for staff.

Popular Compliance Violations: What Auditors Find

Popular violations of ATEX compliance include the use of non-compliant spare parts, lack of certificates of conformity, lack of documentation of compliance, use of electrical equipment in hazardous areas without the required certificates, lack of maintenance and repair reporting, lack of personnel training, and violations of explosion test procedures.

Consequences of violation of requirements: fines, liability

Violation of the requirements of the ATEX standard can lead to fines from 5,000 to 50,000 hryvnias, loss of additional insurance, liability for culpability in explosions and unforeseen events, as well as liability for violations of labor safety legislation. In the event of an explosion due to violation of ATEX requirements, the company that used the wrong equipment is solely to blame.

Conclusion: choosing certified components for safe operation

Ensuring safety in hazardous areas requires strict implementation of the ATEX standard. If replacement parts are required, the selection of certified components is critical. United-D offers a wide range of spare parts certified according to ATEX standards, which ensure safety and reliability in operation. Refer to the UNITEC-D E-Catalog for the appropriate components that meet ATEX requirements and ensure the safety of your installation.

List of used documents

• EN 60079-1:2014 – ATEX standard for explosive areas.
• EN 60079-7:2014 – Requirements for electrical equipment in hazardous areas.
• EN 60079-15:2014 – Requirements for electrical equipment in hazardous areas.
• DSTU 2158-2020 - Requirements for explosive zones.
• DSTU 2157-2020 - Requirements for explosive zones.
• DSTU 2156-2020 – Requirements for explosive zones.

Introduction

Modern requirements for safety, energy efficiency and compliance with regulations require periodic updating of industrial installations, especially in the sector where work with explosive environments. In Ukraine, where industrial enterprises are forced to meet new safety and energy efficiency standards, retrofitting ATEX systems is critical to ensure safety and economic benefit.

Evaluation of the existing system

A detailed assessment of the current system must be carried out before retrofitting. This includes performance analysis, compliance with standards and risk identification. Below is a table of criteria for evaluation:

Modern alternatives

Modern components such as the Heidenhain LS106MIT-MSS ensure high efficiency, reliability and compliance with standards. Below is a comparison table of old and new equipment:

Calculating return on investment (ROI)

The use of modern components provides significant cost savings. Below is a detailed calculation:

Energy consumption: 120 kWh/month → 80 kWh/month

Energy costs: 120 kWh × UAH 0.20/kWh = UAH 24/month

Cost reduction: 40 kWh × UAH 0.20/kWh = UAH 8/month

Operation cost: UAH 1,500/month

Reduction of repair costs: UAH 1,500/month

Total savings: UAH 8 + UAH 1500 = UAH 1508/month

The cost of retrofitting: UAH 5,000

Cost reimbursement: UAH 5,000 / UAH 1,508/month ≈ 3.32 months

Implementation plan

Retrofit should be carried out in phases to minimize production stoppages:

1. Planning: Evaluation of the current system, determination of needs, selection of components.
2. Ordering: Ordering modern components via UNITEC-D E-Catalog.
3. Installation: Replacement of old components with new ones, agreed with technical standards.
4. Confirmation: System testing for compliance with ATEX and other standards.

Technical challenges

Problems such as component incompatibilities, lack of documentation or deviations from standards may arise during retrofitting. The solution includes:

• Use of modern components that meet standards.
• Performing a detailed analysis of the system before replacement.
• Using UNITEC-D technical support to ensure compliance.

Case stage

The ATEX system was retrofitted at the enterprise in Ukraine. After installing the Heidenhain LS106MIT-MSS:

• Efficiency increased from 75% to 92%
• Energy costs decreased by 33%
• Duration without recovery increased from 1500 hours to 5000 hours
• The total savings for the year is UAH 18,096

Confirmation and testing

After installing new components, the system is subject to testing according to the following standards:

• Testing for compliance with ATEX (DSTU 3061:2015)
• Energy efficiency testing (EN 50034)
• Duration test without recovery (ISO 14224)

Acceptance criteria:

• Efficiency more than 90%
• Compliance with ATEX standards
• 30% reduction in energy costs

Conclusion

Retrofitting ATEX systems in existing installations is a necessary step to ensure safety, energy efficiency and compliance with standards. The use of modern components, such as the Heidenhain LS106MIT-MSS, provides significant savings and increased efficiency. For specific components and technical support, visit the UNITEC-D E-Catalog.

List of references

• EU directives on potentially explosive atmospheres (2014/34/EU)
• Standards DSTU 3061:2015, EN 12101-1, ISO 14224
• Manufacturers' guides for ATEX compliance
• UNITEC-D manuals for retrofitting systems

Introduction

Explosive environments are a serious risk for industrial installations, especially in Ukraine, where production is high-density and uses various types of liquids, gases and dusts. ATEX certification is a critical element of the safety and reliability of systems operating in such conditions. This article provides a technical framework for selecting and using ATEX-compliant equipment and using it in real-world production environments.

Fundamental principles

Explosive environments occur due to the presence of gases, vapors or dust that can mix with air and form an explosive mixture. An explosion can occur due to heat transfer, electric current or mechanical friction. ATEX certification sets standards for the production and use of equipment that reduces the risk of explosion.

Technical specifications and standards

ATEX certification meets standards EN 60079-0 to EN 60079-34 that define categories, zones and equipment requirements. Zones are divided into zones 0, 1, 2 for gases and zones 20, 21, 22 for dust. The categories determine the level of explosion risk:

• Category I: High risk of explosion
• Category II: Medium explosion risk
• Category III: Low risk of explosion

The certification meets the following standards:

• EN 60079-0: Definition of zones
• EN 60079-11: Classification of equipment
• IEC 60079-34: Requirements for production and use
• ISO 80079-1: Requirements for production and use

Selection and calculation

The selection of equipment for explosive zones must be made taking into account the following criteria:

1. Zone definition
2. Equipment classification
3. Temperature class requirements
4. Electrical parameters
5. Materials and construction

The equipment dimensions are calculated according to the following formulas:

where:

• Q – required thermal power, kW
• m – mass of the object, kg
• c – heat capacity, J/(kg °C)
• ΔT – temperature difference, °C

Installation and commissioning best practices

When installing equipment in explosive zones, it is necessary:

• Perform grounding and grounding
• Use the external interface that corresponds to the class
• Carry out diagnostics of explosive zones
• Use electronic circuits appropriate for the class

During startup, you must:

• Check for explosive substances
• Use control tools
• Determine the temperature and pressure

Modes of explosion and analysis of causes

Special explosion modes can occur due to:

• Flash explosion
• High pressure explosion
• Dust flare

The reasons for the explosion may be:

• Improper use of equipment
• Insufficient grounding level
• Incorrect zone classification
• High pressure or temperature

Determining the causes of the explosion can be done using:

• The method of visual analysis
• Electrical analysis
• Temperature analysis

Predictive technical support and status monitoring

To support equipment in explosive zones, the following are used:

• Temperature and pressure control
• Electrical control
• Monitoring of explosive zones
• Use of sensors of explosive substances

Using such methods reduces the risk of explosion and ensures safety.

Comparison table

Conclusion and action

ATEX certification is a critical safety element for industrial installations in explosive environments. Equipment that meets standards ensures reliability and safety. United-D GmbH is a reliable supplier of components for the production and operation of equipment in such conditions. You can find the required components on our e-catalog: https://www.unitecd.com/e-catalog/

Sources

• EN 60079-0: 2014
• EN 60079-11: 2014
• IEC 60079-34: 2014
• ISO 80079-1: 2014
• UNITEC-D: Technical documents