Understanding ATEX Zoning: Directives, Compliance, and Reduce Zoning 

What Does ATEX Mean? 

The acronym ATEX originates from the French term “Atmosphères Explosibles,” referring to a series of European Union directives that outline essential safety protocols for equipment and workspaces at risk of explosion due to flammable substances like gases, vapors, or dust. These directives play a critical role in safeguarding both workers and the environment, aiming to mitigate explosion risks within industrial settings and enhance operational safety across diverse industries. Learn more about Explosion Safety here.

ATEX vs. IECEx vs. NFPA

ATEX and IECEx are two essential certification systems for equipment used in explosive atmospheres, with distinct scopes and regulatory frameworks. ATEX, mandated by the European Union Commission, is a legal requirement within the European Economic Area (EEA), rooted in two EU Directives that ensure equipment safety in explosive environments.

IECEx The International Electrotechnical Commission System for Certification to Standards Relating to Equipment for Use in Explosive Atmospheres. Is a global standard developed by industry representatives, including manufacturers, certification bodies, and regulators. Unlike the mandatory ATEX, IECEx is a voluntary system recognized worldwide and adopted by countries like the United States, China, and the UN. This “global certification” framework consists of four schemes: the Certified Equipment Scheme, Certified Services Scheme, Conformity Mark Licensing System, and Certified Competent Persons Scheme, covering both equipment and personnel.

NFPA (National Fire Protection Association) is another important system, primarily used in the United States. It offers comprehensive safety standards for hazardous locations, which classify areas where flammable gases, vapor, or combustible dust may pose a risk. Unlike ATEX and IECEx’s zone classification, NFPA uses a Class/Division system. For example, Class I, Division 1 represents areas where hazardous gases are continuously present, while Class I, Division 2 covers locations where such gases are only present under abnormal conditions.

Technically, ATEX and IECEx standards have been closely aligned since 2005, sharing the same hazardous area classifications (more on this later). ATEX can even base its certification on an IECEx test report. While ATEX addresses compliance within the EU, IECEx provides a globally consistent certification approach, facilitating safer international trade in hazardous area equipment and services. Meanwhile, NFPA’s Class/Division system offers a well-established approach in the U.S., aligning its guidelines with a focus on installation and safety protocols, rather than global certification.

Why Is ATEX Important? 

ATEX guidelines are key to standardizing safety measures throughout the European Union, especially in locations where explosive atmospheres are likely. These guidelines are important because they: 

• Help prevent accidents caused by explosive substances. 
• Ensure safe working environments for employees. 
• Require the use of specific equipment for high-risk areas, fostering best practices and promoting safe handling procedures. 

Why Are There ATEX Guidelines? 

Explosions from hazardous materials can be catastrophic, posing severe risks to human lives and infrastructure. ATEX guidelines provide a comprehensive framework to help industries manage these risks effectively. By implementing clear zoning, equipment specifications, and compliance requirements, the ATEX directives enable businesses to follow safer operational practices and meet legal obligations. 

What is an Explosive Atmospheres? 

An explosive atmosphere occurs when a mixture of air, gases, vapors, mists, or dust becomes flammable. In certain conditions, this mixture can ignite, resulting in an explosion that may have great consequences for both people and buildings. ATEX zones classify such areas based on the probability of these conditions arising, allowing industries to tailor their safety measures to specific risk levels. 

What Are the Primary ATEX Directives? 

There are two primary ATEX directives that govern equipment and zoning in explosive atmospheres: 

1. Directive 1999/92/EC (ATEX 153 Directive): Also known as the “workplace directive,” this directive emphasizes zoning and safety protocols within workplaces. It requires employers to classify areas with explosion potential and implement necessary safety precautions for employee protection. 
2. Directive 2014/34/EU (ATEX 114 Directive): This directive covers equipment and protective systems used in explosive atmospheres. It defines requirements for the design, manufacture, and testing of equipment to ensure safe operation under such conditions. 

Classification of ATEX Zoning (ATEX 153) 

ATEX zoning is categorized for gases and dust, each with three zones. These classifications help to assess the frequency and duration of explosive atmospheres, guiding safety measures and equipment selection. 

For Gas – EN 60079-10-1 

• Zone 0: Locations where an explosive gas atmosphere is continuously present. Equipment here must endure extreme conditions. 
• Zone 1: Locations where an explosive gas atmosphere is likely to occur during regular operations. Equipment must withstand foreseeable hazards. 
• Zone 2: Locations where explosive gas atmospheres are unlikely under normal operation, but if they do occur, they’re brief. Equipment in this zone faces a lower risk level. 

For Dust – EN 60079-10-2 

• Zone 20: Locations with a constant presence of combustible dust. Equipment must be robust for extreme dust conditions. 
• Zone 21: Locations where combustible dust is likely to form under normal conditions. Equipment must handle dust-related hazards. 
• Zone 22: Locations where dust clouds are unlikely under normal conditions and brief if they occur. Equipment faces lower risks but still needs ATEX certification. 

ATEX Equipment Certification (ATEX 114) 

All equipment used in ATEX zones must comply with specific safety requirements and hold proper certifications. Certification confirms that the equipment meets European safety standards and is suitable for explosive atmospheres.  

The EN 60079 series applies to electrical equipment, while EN 13463 and EN ISO 80079 cover non-electrical equipment. Businesses must ensure that equipment in ATEX zones is certified for the zone’s specific risks. 

Best Practices for ATEX Compliance 

To effectively apply ATEX guidelines, businesses should: 

• Conduct Risk Assessments: Begin with a thorough evaluation of areas at risk of explosive atmospheres, understanding the frequency and probability of these risks. 
• Provide Employee Training: Make sure employees working in ATEX zones are trained in safe handling practices and ATEX compliance. 
• Use Certified Equipment: Select equipment certified to ATEX standards for specific zones, covering both electrical and non-electrical tools. 
• Install Ventilation and Extraction Systems: Use these systems to reduce hazardous substances in the air, lowering the chance of ignition. 
• Perform Regular Compliance Checks: Routinely inspect, maintain, and update equipment and systems to meet ATEX standards. 

All should be listed/documented in the ESD (Explosion Safety Document), which is mandatory to have and maintain.

Methods to prevent or mitigate an Explosion atmosphere

There is a certain methodology for reducing and mitigating the risk of explosions. By applying this approach, it is often possible to minimize or even reduce the extent of ATEX zones. 

1. Preventing: The first focus should be on minimizing dust accumulation through regular cleaning, installing dust collection systems, and using enclosed material handling systems. Maintaining appropriate humidity levels also helps reduce airborne dust. 
2. Eliminate Ignition Sources: The second key step is eliminating ignition sources. Static electricity must be controlled by grounding equipment, and explosion-proof electrical systems should be used. Control of hot work like welding and monitoring equipment temperature are also essential for preventing ignition. 
3. Limit the Effects of an Explosion: Lastly, it’s crucial to limit the impact of an explosion by using explosion venting systems, suppression systems, and pressure relief measures. Physical barriers and proper staff training further help to contain and manage the situation in case of an explosion. 

Best ways to reduce ATEX zoning 

Ventilation: ZONE REDUCING 

Ventilation helps to reduce hazardous zones by diluting and dispersing potentially explosive atmospheres. By introducing fresh air and exhausting potentially dangerous gases or dust, the concentration of combustible material is lowered to below LEL, making it less likely to reach explosive levels. Good ventilation systems prevent the accumulation of explosive mixtures in enclosed areas, therefore reducing the ATEX zones, or in some cases, lowering them to less critical zones (e.g. Zone 1 to Zone 2 for gases). 

Extraction: ZONE ELIMINATION 

Extraction systems directly remove combustible dust or gases from the atmosphere, often at the source. By capturing and removing hazardous materials before they have a chance to accumulate, extraction will prevent the possibility of an explosion. If the Extraction system is designed and maintained properly, the area where the extraction is applied may not require ATEX zoning at all, as the potentially explosive material is continuously removed, keeping the concentration levels below the threshold that would require zoning. 

Housekeeping: ZONE REDUCING 

Housekeeping, which includes regular cleaning and maintenance to remove dust and debris, can also reduce the spread of combustible materials. Accumulated dust can be a major contributor to ATEX zoning, especially in areas where dust settles and can become airborne. Consistent and effective cleaning with a Central Vacuum Cleaning System reduces the overall presence of combustible dust. Which can lower the risk of ignition and reduce the ATEX zones, or in some cases, lowering them to less critical zones (e.g. from Zone 21 to Zone 22 for dust or Zone 1 to 2 for gases).

Which solutions to choose?

ATEX zoning can be complex and varies greatly depending on the specific conditions of each environment. Determining the right zoning and mitigation methods requires a thorough understanding of the unique hazards present at your site. Factors like the type of substances involved, equipment used, and operational processes all play a role in defining ATEX zones. Therefore, it’s crucial to consult with someone who can assess your particular situation and recommend the best cost-effective solutions. This ensures not only compliance with safety regulations but also the most effective explosion handling methods for reducing or managing explosive risks. So please contact us today and share you Explosion Safety Challenge.