The presence of highly explosive industrial environments poses complex challenges for the safety of plants and workers. When flammable chemicals are used in production processes, even the slightest spark can trigger catastrophic explosions. Therefore, managing ATEX environments requires the adoption of stringent safety protocols and the use of cutting-edge technologies. But what are the best practices for classifying explosive risks and choosing the most suitable devices to prevent them? How can productivity and safety be reconciled in ATEX environments?
ATEX: what is it and why is it so important
ATEX (ATmosphères EXplosibles) is a European directive that aims to ensure safety in environments where flammable, explosive, or combustible substances are present. The ATEX Directive imposes certain essential safety requirements that must be met by all electrical and mechanical devices installed in these high-risk environments to prevent explosions.
The ATEX Directive is composed of two main pieces of legislation: Directive 2014/34/EU (also known as “ATEX Product”), which concerns equipment and protective systems intended for use in potentially explosive atmospheres, and Directive 1999/92/EC (“ATEX Worker”), which concerns the health and safety of workers who may be exposed to the risk of explosive atmospheres.
There are many reasons why the ATEX Directive is so important: first, it requires companies to classify potentially explosive areas, identifying the locations where explosive atmospheres may occur and adopting the necessary prevention and protection measures. Furthermore, ATEX defines specific construction and installation requirements for electrical equipment, ventilation systems, protective devices, and other elements that may constitute a source of ignition in potentially explosive environments. The main sectors affected by the ATEX regulation are the chemical, petrochemical, pharmaceutical, petroleum, paint, wax, and cosmetics industries, sugar refineries, mills, and sawmills, as well as the mining, transportation, and storage of dangerous goods sectors.
Correct implementation of the ATEX directive significantly improves safety in these environments, safeguarding the integrity of facilities, the health of workers, and the surrounding environment. For this reason, ATEX compliance is a must for companies that work with flammable substances. The design and implementation of appropriate industrial networking systems is essential to ensuring compliance with ATEX requirements, as is the use of ATEX-certified technologies for components used in classified environments.
ATEX Technologies for Explosive Industrial Environments
ATEX compliance requires the adoption of specific technical and organizational measures to prevent the ignition of explosions in industrial environments defined as “ATEX zones.” ATEX zones are classified as follows:
– Zone 0: area with a potentially explosive atmosphere present permanently or for extended periods;
– Zone 1: area with an potentially explosive atmosphere occasionally present during normal operation;
– Zone 2: area in which the formation of an explosive atmosphere is unlikely. ATEX technologies include all equipment specifically designed to operate safely in ATEX zones, such as:
– Gas detection systems for continuous monitoring of the atmosphere;
– Explosion-proof electrical panels with explosion-resistant housings;
– Motors with overheating protection;
– Explosion-proof lighting fixtures;
– Electrical system grounding and decontamination systems.
Installing suitable ATEX components and following specific safety procedures are essential to ensure the protection of people, the environment, and equipment in explosive industrial environments. With the advent of Smart Industry, ATEX instrumentation is also evolving with wireless sensor solutions and intrinsically safe equipment featuring integrated automation and control, for more efficient and safe management of ATEX environments.
ATEX Devices: How to Choose the Most Suitable
Choosing the most suitable ATEX devices for a given classified environment must take several factors into account to ensure the highest levels of safety and efficiency. First and foremost, it is essential to choose ATEX-certified components, meaning they comply with Directive 2014/34/EU. The ATEX marking indicates the device’s group and category, which must correspond to the zone classification of the area in which it will be installed. For example, Category 1 devices are required for Zone 0, while Category 3 devices are suitable for Zone 2. Explosion protection must also be compatible with the flammable materials present (gas, vapors, or dust).
In addition to the ATEX category, it is important to evaluate other parameters such as the ambient operating temperature, IP protection, and resistance to shock, vibration, and corrosion. For the best choice, we recommend relying on qualified manufacturers of ATEX equipment and seeking technical advice to identify the solution best suited to the specific explosive risk and installation environment.
With the spread of Smart Industry, the offering of ATEX devices has expanded to include more advanced and flexible solutions: controllers and PLCs with digital communication protocols, intrinsically safe wireless devices, and explosion-proof video surveillance systems. The integration of these enabling ATEX technologies allows for the implementation of automated, interconnected, and intelligent architectures even in the most critical environments
