ATEX Compliance for Manufacturers: How to Determine Whether Your Equipment Meets the Requirements

Manufacturers designing equipment for chemical processing, oil and gas, food production, pharmaceutical manufacturing, mining and other industrial environments may need to consider an additional hazard during product development: the potential for an explosive atmosphere.

Where equipment is intended for use in an environment containing flammable gases, vapours, mists or combustible dust, ATEX compliance may become an important part of the product conformity process.

Determining that a product will operate in a hazardous environment is only the beginning. Manufacturers need to understand whether ATEX legislation applies to their equipment, how the intended operating environment affects equipment selection, what potential ignition sources exist and which conformity assessment route is appropriate.

Getting these decisions right early can help prevent expensive redesign, additional testing and delays when equipment is ready to enter the European market.

What Does ATEX Compliance Mean for a Manufacturer?

The ATEX Directive 2014/34/EU applies to certain equipment and protective systems intended for use in potentially explosive atmospheres. For manufacturers, compliance is therefore not simply about purchasing ATEX-approved components or adding an Ex marking to finished equipment. The complete product needs to be considered.

·        The intended operating environment

·        Possible sources of ignition

·        Electrical and mechanical components

·        Equipment group and category

·        Applicable essential health and safety requirements

·        Relevant harmonised standards

·        Testing and technical evidence

·        Conformity assessment requirements

·        Technical documentation supporting the final product

Manufacturers uncertain about the requirements for their equipment can review our ATEX compliance services for further guidance on the conformity process.

First Question: Will the Equipment Be Used in an Explosive Atmosphere?

Before considering certification or documentation, manufacturers should understand the environment in which their equipment will operate. Potentially explosive atmospheres can occur where air mixes with flammable gases, vapours, mists or combustible dust in conditions where ignition could cause combustion to spread through the mixture.

These environments are not limited to oil refineries or chemical plants. Risks can also arise in facilities handling flour, grain, wood dust, solvents, powders, fuels and other combustible substances. Understanding the intended installation environment is therefore essential when determining whether ATEX requirements are relevant.

Understanding ATEX Zones

Hazardous areas are classified according to how frequently an explosive atmosphere is expected to occur and how long it is likely to remain. For gases, vapours and mists, the commonly recognised classifications are Zones 0, 1 and 2. For combustible dust, the equivalent classifications are Zones 20, 21 and 22.

·        Zone 0: an explosive gas atmosphere is present continuously, frequently or for long periods.

·        Zone 1: an explosive gas atmosphere is likely to occur occasionally during normal operation.

·        Zone 2: an explosive gas atmosphere is unlikely during normal operation and, if it occurs, exists only briefly.

·        Zone 20: combustible dust is present continuously, frequently or for long periods.

·        Zone 21: combustible dust is likely to occur occasionally during normal operation.

·        Zone 22: combustible dust is unlikely during normal operation and, if it occurs, exists only briefly.

The intended zone influences the level of protection required from equipment, so manufacturers should establish the operating environment before making assumptions about product design, components or conformity assessment.

Equipment Categories Matter Too

ATEX categorises equipment according to the level of protection required. For many non-mining applications, equipment is divided into Categories 1, 2 and 3. Broadly, Category 1 provides a very high level of protection, Category 2 a high level, and Category 3 a normal level for its intended conditions.

The relationship between the intended zone and equipment category is fundamental. A product designed for a lower-risk environment should not automatically be assumed suitable for a higher-risk hazardous area simply because individual components carry appropriate markings.

Electrical Equipment Is Not the Only ATEX Concern

A common misconception is that ATEX applies only to electrical products. Mechanical equipment can also create ignition sources. Potential hazards may include hot surfaces, mechanically generated sparks, friction, static electricity or other energy capable of igniting an explosive atmosphere.

Pumps, gearboxes, fans, mixers, conveyors and other mechanical equipment may therefore require an appropriate ignition-hazard assessment depending on their design and intended application.

Does ATEX Always Require a Notified Body?

Not necessarily. The conformity assessment route depends on factors including equipment group, category, type of equipment and the level of protection required. Some equipment may follow a manufacturer-controlled route, while other products require involvement from a Notified Body.

Professional CE marking assistance can also help manufacturers understand how ATEX interacts with other applicable European product legislation.

ATEX May Not Be the Only Requirement

Industrial equipment frequently falls under more than one European regulatory framework. Equipment designed for an explosive atmosphere may also incorporate machinery, electrical systems, pressure equipment or electronic controls. ATEX compliance should therefore not be treated as an isolated exercise.

Manufacturers need to identify all legislation applicable to the finished product and demonstrate conformity with the combined requirements before applying the appropriate marking.

Build the Technical Evidence as the Product Develops

Waiting until a product is finished before considering ATEX documentation can create avoidable problems. Technical evidence should develop alongside the design.

Depending on the product and conformity route, documentation may need to contain design information, drawings, component details, applicable requirements, risk assessments, ignition-hazard assessments, standards used, calculations and test evidence. The objective is to demonstrate why the finished equipment satisfies the applicable requirements.

Where equipment is also subject to broader CE requirements, manufacturers can review our CE marking guidance to understand how technical documentation fits into the overall conformity process.

Common ATEX Compliance Mistakes

Several problems can arise when ATEX is considered too late. One is assuming that individually compliant components automatically make the completed assembly compliant. Another is selecting equipment before confirming the intended hazardous-area classification.

Manufacturers may also focus heavily on electrical ignition risks while overlooking mechanical ignition sources. Documentation can create further problems when design changes, component substitutions or customer-specific modifications are introduced without reassessing the original conformity evidence.

A Practical ATEX Checklist for Manufacturers

·        Is the equipment intended for use in a potentially explosive atmosphere?

·        What substances could create the explosive atmosphere?

·        What hazardous zone will the equipment operate in?

·        What equipment group and category are appropriate?

·        What potential electrical and mechanical ignition sources exist?

·        Which ATEX requirements and standards apply?

·        Is third-party Notified Body involvement required?

·        Has the necessary testing and assessment been completed?

·        Does the technical documentation support the final product configuration?

·        Have other applicable CE requirements also been considered?

·        Is the required declaration and product marking correct?

Plan ATEX Compliance Early

ATEX compliance is ultimately a product-engineering and risk-management process. The strongest approach is to identify the intended environment, equipment classification, ignition hazards and conformity route while the product is still being developed. Doing so gives manufacturers more opportunity to address problems through design rather than expensive modifications at the end of the project.

CE Marking Authority supports manufacturers with ATEX assessments, technical documentation, testing strategies and wider product conformity requirements.

If you are developing equipment for use in a potentially explosive atmosphere, explore our ATEX Directive compliance support to understand the requirements applicable to your product.