ATEX Audits of Machines and Installations
What does a facility gain from a systematic approach?
ATEX Audits and Assessments of Machines and Installations
Many industrial facilities use machines and technological installations operating in environments where an explosive atmosphere may occur. In such conditions, the proper selection of equipment and its compliance with explosion safety requirements becomes particularly important.
ATEX Audits and Assessments of Machines and Installations allow you to verify whether the equipment used meets regulatory requirements and can be safely operated in explosion hazard zones.
EHS Consulting offers comprehensive ATEX audits of industrial installations and conformity assessments of machines operating in Ex zones, supporting companies in identifying hazards and implementing effective solutions that increase the level of safety.
What is an ATEX audit of machines and installations?
An ATEX audit is a specialist technical analysis aimed at assessing whether the machines, equipment and technological installations used in a company are adapted to operate in an explosion-hazardous environment.
During the audit, the following are analysed, among others:
- compliance of equipment with ATEX directive requirements,
- correct selection of equipment for explosion hazard zones,
- potential ignition sources,
- technical solutions reducing the risk of explosion,
- technical condition of installations.
The goal of the audit is hazard identification and indicating the actions that need to be taken to ensure the safe operation of machines and installations in an explosion-hazardous environment.
When should an ATEX audit be conducted?
ATEX Audit of Machines and Installations is particularly recommended in situations such as:
- commissioning of a new technological installation,
- modernisation of a production line,
- change of chemical substances used,
- implementation of new machines at the workplace,
- preparation for inspection by supervisory authorities,
- doubts regarding compliance of equipment with ATEX requirements.
Regular explosion safety audits allow potential hazards to be detected at an early stage and costly failures or accidents to be avoided.
ATEX Standard
ATEX (from French atmosphères explosibles) is the EU safety regulation system for potentially explosive atmospheres — wherever flammable gases, vapours, mists or dusts may appear in the air at concentrations capable of exploding: paint shops, mills, grain silos, gas installations, refineries, solvent warehouses, wastewater treatment plants and similar facilities.
Two pillars of the system
| ATEX 114 — Directive 2014/34/EU | ATEX 153 — Directive 1999/92/EC | |
|---|---|---|
| Who it applies to | Manufacturer of equipment and protective systems | Employer / installation user |
| Polish transposition | Reg. of the Minister of Development of 6 June 2016 (Journal of Laws 2016, item 817) | Reg. of the Minister of Economy of 8 July 2010 (Journal of Laws 2010, No. 138, item 931) |
| Key obligations | Conformity assessment (involving a notified body for cat. 1 and 2), technical documentation, EU declaration of conformity, CE + ⬡Ex marking | Explosion risk assessment, zone classification, preparation and updating of EPD, equipment selection, marking, training, supervision |
Hazard Zone Classification
| Zone | Medium | Frequency and duration of explosive atmosphere |
|---|---|---|
| 0 | Gases, vapours, mists | Continuously or for long periods of time |
| 1 | Gases, vapours, mists | Occasionally under normal operating conditions |
| 2 | Gases, vapours, mists | Rarely and only for short periods |
| 20 | Combustible dusts | Continuously or for long periods of time |
| 21 | Combustible dusts | Occasionally under normal operating conditions |
| 22 | Combustible dusts | Rarely and only for short periods |
Equipment Categories and Zones
| Equipment category | Permitted zone | Required protection level |
|---|---|---|
| 1 (mining: M1) | 0 / 20 | Highest — device safe even with two independent failures |
| 2 (mining: M2) | 1 / 21 | High — protection maintained even in case of device failure |
| 3 | 2 / 22 | Normal — protection under correct operating conditions |
Ex Equipment Marking — how to read the code?
Every device approved for Ex zones has a full marking code, e.g. Ex II 2 G Ex db IIC T4 Gb. Below is the meaning of each element:
| Element | Meaning |
|---|---|
| Ex | Device meets ATEX Directive 114 requirements |
| II | Equipment Group II — surface (I = underground mining) |
| 2 G | Category 2, medium: gas (G = gas / D = dust) |
| db | Type of protection: flameproof enclosure “d”, EPL level “b” |
| IIC | Gas subgroup — IIC is the most demanding (hydrogen, acetylene) |
| T4 | Temperature class — max. surface temperature 135 °C |
| Gb | Equipment Protection Level: gas, level “b” (high) |
Key harmonised standards
The essential requirements of Directive 2014/34/EU are most commonly met by applying harmonised standards from the PN-EN IEC 60079 series:
- PN-EN IEC 60079-10-1 — classification of zones endangered by gases and vapours
- PN-EN IEC 60079-10-2 — classification of zones endangered by dusts
- PN-EN IEC 60079-14 — design, selection and installation of Ex electrical installations
- PN-EN IEC 60079-0 — general requirements for Ex equipment
Employer’s Obligations — Summary
- Conduct an explosion risk assessment and document the results
- Classify facility areas into hazard zones (0, 1, 2 / 20, 21, 22)
- Prepare and update the Explosion Protection Document (EPD)
- Ensure Ex zone marking and implement safe work procedures
- Conduct training for employees working in Ex zones
- Use only equipment with a category matched to the specific zone
- Ensure continuous supervision, inspection and maintenance of Ex installations
⚠️ PIP and UDT inspections — violation of ATEX requirements is one of the most frequently checked areas. Lack of an EPD or mismatched equipment for the zone are typical reasons for a facility work stoppage.
The above information is for informational purposes only. For a specific implementation, refer to the full text of regulations and standards or consult an explosion safety specialist.
What does an ATEX audit cover maszyn i instalacji?
Explosion safety audits cover a comprehensive analysis of technological installations and equipment operating in explosion-hazardous environments.
Analysis of technological installations
During the audit, the technological processes occurring at the workplace and the installations in which explosive atmospheres may arise are analysed.
The aim of this analysis is to identify places particularly exposed to the formation of an explosive mixture.
Verification of equipment operating in Ex zones
The compliance of the equipment used with ATEX requirements and its correct selection for specific explosion hazard zones is checked.
Analiza obejmuje m.in.:
- ATEX markings of devices,
- technical documentation,
- conformity certificates,
- operating parameters of devices.
Identification of potential ignition sources
One of the most important elements of the audit is the identification of potential ignition sources, such as:
- electrical installations,
- hot surfaces of equipment,
- mechanical sparks,
- electrostatic discharges.
Assessment of explosion protection measures
During the audit, the technical solutions used in the facility to reduce the risk of explosion are also analysed, such as:
- explosion relief systems,
- explosion suppression systems,
- gas detection systems,
- ventilation systems.
Conclusions and recommendations
After the audit is completed, a report is prepared containing:
- identification of explosion hazards,
- assessment of installation compliance with ATEX requirements,
- identification of irregularities,
- recommendations for improving safety.
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