Selection

ATEX GUIDE

Basic concepts for protection

in explosive atmospheres
Guide to the ATEX directives

> CONTENTS

1. INTRODUCTION .................................................................3 5. EQUIPMENT SELECTION ..............................................16

2. ATEX DIRECTIVE 94/9/EC: EQUIPMENT ........................4 6. EVOLUTION OF DUST STANDARDS ............................19
3. TYPES OF PROTECTION ................................................9 7. APPLICATION EXAMPLES ............................................20
4. ATEX DIRECTIVE 99/92/EC: WORKPLACE ..................12 8. AMERICAN STANDARDS ..............................................31

REFINERIES FUELTANKS STORAGE

INTERNAL COMBUSTION SYSTEMS JUMBO TANK LOGISTICAL STORAGE FACILITIES

PETROL-CHEMICAL REFINERY PLANTS SHIP BUILDING

INDUSTRIAL POWER PLANTS GASIFICATION PLANTS

LOGISTICAL MARITIME-BUNKERING FACILITIES UPSTREAM-MARITIME OFF SHORE PLATFORMS

2
> 1. INTRODUCTION

What is ATEX?

Guide to the ATEX directives

“ATEX” is the acronym for “ATmosphere EXplosive”, i.e.,
explosive atmosphere.
An explosive atmosphere is a mixture of flammable gases,
vapours, mists or dusts with air, under specific atmospheric
conditions in which, after ignition has occurred, combustion
propagates to the flammable mixture.
an explosive atmosphere and specifies the basic criteria by
In order for a potentially explosive atmosphere to form, the
which the equipment is selected within these zones. The
flammable substances must be present in a certain
ATEX Directive 94/9/EC was implemented in Italy with
concentration. If the concentration is too low (lean mixture)
Legislative Decree 126/98 and applies to products placed
or too high (rich mixture), no explosion occurs; instead there on the market and/or in service after 1 July 2003. The ATEX
is just a slow combustion reaction or no reaction at all.
Directive 99/92/EC was implemented in Italy with Legislative
Thus the explosion can occur only in the presence of an Decree 233/03 and came into effect on 10 September 2003.
ignition source and when the concentration is within the The subsequent Legislative Decree 81/08 of 9 April 2008
explosive range of the substances, i.e., between the lower (particularly Title XI- Protection from explosive atmospheres)
explosive limit (LEL) and upper explosive limit (UEL). The and its update (Lgs.D. 106/2009 of 3/08/09, in effect as of 20
explosive limits depend on the ambient pressure and the
August) have since surpassed Lgs.D. 233/03. The figure
percentage of oxygen in the air. below provides a schematic overview of the ATEX Directives
and their correlation.
ATEX DIRECTIVES
The European Union, regarding the hazard caused a SCOPE OF THE ATEX GUIDE
potentially explosive atmosphere, has adopted two
This document is a simple guide to the ATEX Directives, their
harmonized directives on health and safety, known as meaning and how to select the best products suited for
ATEX 94/9/EC (also ATEX 100a) and ATEX 99/92/EC (also
explosion hazard areas.
ATEX 137).
The scope of the TECHNOKONTROL guide is to
The ATEX Directive 94/9/EC sets out the Essential Safety
support, and not replace, the ATEX Directives by trying
Requirements for products and protective systems intended
to provide valid information about the primary types of
for use in potentially explosive atmospheres and the
installations on which the ATEX Directives have an impact
respective conformity assessment procedures. The ATEX
and inform the installer about the criteria for recognizing,
Directive 99/92/EC, on the other hand, defines minimum selecting and correctly installing the TECHNOKONTROL
health and safety requirements for workplaces with a
products and solutions whose characteristics best suit the
potentially explosive atmosphere; in particular, it divides the
environment in question.
workplaces into zones according to the probability of having

ATEX

ATEX 94/9/EC ATEX 1999/92/EC

(ATEX 100a) EX
(ATEX 137)

Workplace Directive Minimum

Equipment Directive
requirements for workplaces (health
Essential Safety Requirements (ESR)
and safety of the workers)

Categories 1, 2, 3 (group II) Risk analysis

Categories M1, M2 (group I) (area classification, explosion protection document)

Verification of conformity Selection of the equipment

- Product tests and certification Identification of the zones -

- Quality audits Equipment selection -
- Declaration of conformity, safety instructions Declaration of conformity, safety instructions -

3
Guide to the ATEX directives

> 2. ATEX DIRECTIVE 94/9/EC: EQUIPMENT GROUP II PRODUCTS

The ATEX Directive has been effective throughout the European The surface equipment (group II) is divided into 3 categories,
Union since 1 July 2003, replacing the various existing based on the level of protection (zone of use); the categories
are identified by the number 1, 2, 3 followed by the letter G
national and European legislations regarding explosive
(Gas) or D (Dust).
atmospheres; after that date it has been possible to market • category 1: equipment or protective systems that guarantee
only those products conforming to the directive and a very high level of protection;
supplied with the ATEX CE marking and EC declaration of • category 2: equipment or protective systems that guarantee
conformity. It applies to all the electrical and mechanical a high level of protection;
equipment intended for use in explosion hazard areas, • category 3: equipment or protective systems that guarantee
ranking among the directives that allow free trade of the a normal level of protection.
goods and define the essential safety requirements (ESR) of
the equipment which it covers. In particular, the directive CONFORMITY PROCEDURES
defines the product categories and the characteristics the For marking purposes, there are various conformity
products must satisfy in order to be installed in explosion procedures depending on the product and the category to
hazard areas. which it belongs.
It also describes the procedures that must be followed in order All category 1 and category 2 electrical equipment must
to obtain conformity. mandatorily be certified by ATEX Notified Bodies, i.e.,
The Directive’s field of application also extends to safety, those bodies to which the national authority has assigned
control and regulation devices that are installed outside the the task of verifying conformity with the Directive (in Italy, for
potentially explosive area, but on which the safety of the example: IMQ, CESI, ICEPI, TUV, etc.).
products installed in the explosive atmosphere depend. The updated list of ATEX Notified Bodies (NB) is available on
the site:
PRODUCT CLASSIFICATION http://ec.europa.eu/enterprise/newapproach/nando/
The directive includes mining and surface installation materials For companies that manufacture category 1 and category 2
since the hazard, protective measures and test methods are electrical equipment, the notification and monitoring of the
similar for both materials. The primary distinction is made with quality system through an ATEX NB is also mandatory; the
the division of the materials into two groups. identification number of the body is reported on the plate
•group I: products to be used in gassy mines; along with the CE marking.
•group II: equipment intended for use on the surface. Self-certification is provided for all category 3 equipment
Directive 94/9/EC classifies the products in categories, in with internal manufacturing control; in TECHNOKONTROL’s
relation to the level of protection and based on the degree of case, the manufacturing control is fulfilled by the ISO 9001: 2008
riskiness of the environment where they will be installed. company quality certification, issued by CSQ. The
manufacturer must prepare the technical documentation that
GROUP I PRODUCTS demonstrates the equipment’s conformity with the
The mining products are divided into 2 categories: requirements of the Directive; the documentation must remain
category M1: equipment or protective systems that guarantee available for at least 10 years after the last introduction on the
a very high level of protection; market.
category M2: equipment or protective systems that guarantee All products (category 1, 2 and 3) must mandatorily be
a high level of protection; they must be able to be disconnected accompanied by the written EC declaration of conformity
in the presence of the gas. and the instructions for use.
The table below specifies the type of certification required
based on the category of the products.

Declaration
Product certification Company certification
Product category Self-certification of conformity and
by NB by NB
instructions for use
M1 YES YES NO YES
M2 YES YES NO YES
1G YES YES NO YES
1D YES YES NO YES
2G YES YES NO YES
2D YES YES NO YES
3G Optional NO YES YES
3D Optional NO YES YES

4
MARKING

The products must be equipped In addition to the data required by the ATEX Directive, the

Guide to the ATEX directives

with the appropriate identification plate must also indicate the type of protection as provided for
plate which must have, in by the standard and the information useful for correct
addition to the CE marking, identification and use of the product.
the specific marking of explosive protection (Epsilon-x, in The table below specifies the main information provided on
the hexagon) followed by the group (I or II) and category; for the product plates with relative explanatory notes and their
group II, the letter G is added for equipment for Gas while meaning, with reference to the symbol numbers on the
equipment for dust is identified by the letter D (Dust). example plate (see page 7).

GENERAL INFORMATION

N° Marking Meaning Variants

1 TECHNOKONTROL Manufacturer -

Via Costa Erta 15 PARRE Manufacturer’s

2 -
(BG) – ITALY address

Product
3 Code 644.xxx-yyy -
designation

Year
4 2007 -
of manufacture

For categories 1 and 2

5 Conformity mark it must be followed by the number
of the notified body (*)

Specific marking
6 -
of explosive protection

I: electrical equipment for mines

7 II Equipment group II: electrical equipment
for surface installations

1 for category 1
8 2 Product category 2 for category 2
3 for category 3

G: gas
Type of explosive
9 GD D: dust
atmosphere
GD: gas and dust

(*) Number (4-digit number) of the notified body responsible for ATEX company monitoring (for example: the number 0051 corresponds to IMQ,
the number 0722 corresponds to CESI, etc.).

5
Guide to the ATEX directives

GAS (SPECIFIC INFORMATION)

N° Marking Meaning Variants

Conformity with
10 Ex harmonized -
European standards

Types of protection for GAS:

- “d”: flameproof enclosure
- “px” or “py” or “pz”: pressurized
apparatus, level of protection “px” or
“py” or “pz”
- “q”: powder filling
- “o”: oil immersion
Type of - “e”: increased safety
11 e
protection applied - “ia” or “ib” or “ic”: intrinsic safety, level of
protection “ia” or “ib” or “ic”
- “nA”: type of protection “nA”
- “nC”: type of protection “nC”
- “nL”: type of protection “nL”
- “nR”: type of protection “nR”
- “ma” or “mb”: encapsulation, level of
protection “ma” or “mb”

Temperature class (Group II):

T1 = 450°C
Temperature class =
T2 = 300°C
maximum temperature
12 Tx T3 = 200°C
that the electrical
T4 = 130°C
equipment can reach
T5 = 100°C
T6 = 85°C

DUST (SPECIFIC INFORMATION)

Types of protection for DUST:

- “tD”: protection by enclosure
Type of
13 tD - “pD”: type of protection “pD”
production applied
- “iD”: Intrinsic safety protection
- “mD”: protection with encapsulation

There are 2 test methods possible in

Test method (A or B) and compliance with the standard EN 61242-1:
14 A21
installation zone method A or method B, followed by the
zone in which the product may be installed

IP6X: apparatus suitable for Zone 22

with the presence of conductive dust
15 IP66 Degree of protection (IP) IP5X: apparatus suitable for Zone 22
with the presence of non-conductive
dust

Maximum surface
temperature Tyy°C: maximum surface temperature of
16 Tyy
that the electrical the equipment expressed in °C
equipment can reach

6
ADDITIONAL INFORMATION

Guide to the ATEX directives

N° Marking Meaning Variants

Indicates the ATEX

17a U “U”: indicates an EX component
components

“X”: indicates the presence of special

Particular additional
17b X conditions for safe use (to be checked on
information
the certificate or in the instructions for use)

Ambient
18 Ta –xx°C to +xx°C If not indicated, the range is: -20°C +40°C
temperature range

MARKING EXAMPLE

1 17a 2

3
Cod. 644.xxxx-yyy Year xxxx 4
S/N xxxxxxxxx V xxxx V
SIRA08ATEX3042 U I xxxx A
18 P max xxxx W
12
11 0051
Ex e II Tx Ta -xx° to +xx°C X 5
10 Ex tD A21 IP66 Tyy°C
6
13 II 2 GD
9
14 DO NOT OPEN WHEN ENERGIZED 8
IN PRESENCE OF EXPLOSIVE ATMOSPHERE 7

15 16 17b

7
Guide to the ATEX directives

REFERENCE STANDARDS FOR ELECTRICAL EQUIPMENT

The list below specifies the primary standards applicable for the construction and certification of the equipment, subdivided for
gas and dust.

ELECTRICAL EQUIPMENT FOR GAS

IEC Standard EN Standard Contents

IEC 60079-0 EN 60079-0 General requirements

Construction and testing of flameproof enclosures “d” for

IEC 60079-1 EN 60079-1
electrical equipment

IEC 60079-2 EN 60079-2 Electrical equipment, type of protection “p”

IEC 60079-5 EN 60079-5 Powder filling “q”

IEC 60079-6 EN 60079-6 Oil immersion "o"

IEC 60079-7 EN 60079-7 Increased safety "e"

IEC 60079-11 EN 60079-11 Intrinsic safety "i"

IEC 60079-15 EN 60079-15 Electrical equipment with type of protection “n”

IEC 60079-18 EN 60079-18 Encapsulation "m"

ELECTRICAL EQUIPMENT FOR DUST

IEC Standard EN Standard Contents

General requirements for equipment for use in atmospheres

with the presence of dust. (This will be replaced by the
IEC 61241-0 EN 61241-0
standard IEC 2007/ EN 2009, which will be valid for both gas
and dust)

Protection by enclosures “tD”. (This will be replaced by the

IEC 61241-0 EN 61241-1
standard IEC/EN 60079-31)

IEC 61241-4 EN 61241-4 Protection by pressurization “pD”

IEC 61241-2 EN 61241-11 Protection by intrinsic safety “iD”

IEC 61241-11 EN 61241-18 Protection by encapsulation “mD”

Note: Always check the validity of the current standards on the site: http://www.ceiweb.it

8
> 3. TYPES OF PROTECTION

FLAMEPROOF ENCLOSURE PROTECTION BY DUST-PROOF

Guide to the ATEX directives

ENCLOSURE

Marking ”Ex d” II 2G, Marking “Ex tD” II 2D,

standard IEC 60079-1, zone 1, 2 standard IEC 61241-1, zone 20, 21, 22

Principle Principle
The ‘Ex d’ type of protection is the only type of protection The ‘Ex tD’ type of protection is based on the protection by an
based on the containment of the explosion. enclosure which is sealed to the penetration of dust and limits
The electrical components that could ignite an explosive the surface temperature. The electrical components that could
atmosphere are located inside an enclosure which can ignite an explosive atmosphere (high temperatures, sparks,
withstand the pressure of an explosion of the explosive mixture etc.) are located inside enclosures with degree of protection
which has formed inside due to the penetration of a flammable IP6X; in zone 22 with non-conductive dust the degree of
gas or vapour (pressure tightness); the enclosure must also protection IP5X is allowed. Furthermore, the outer surface
prevent the transmission of the explosion to the explosive temperature of the equipment is kept below the maximum
atmosphere surrounding the enclosure (flameproof). surface temperature T, in relation to the maximum temperature
Applications for cloud TCL and layer Tl provided for in the installation site.
Various electrical equipment which, during normal operation, Applications
give rise to sparks or high temperatures: switches, disconnectors, Switches, control units, motors, transformers, lamps,
lamps, control and signal units, motors, MV/LV transformers, instrumentation and generally all the equipment which, during
instrumentation, etc. normal operation, could ignite a cloud or layer of combustible
dust (e.g., due to arcs, sparks or hazardous temperatures).

PRESSURIZED APPARATUS PROTECTION BY INCREASED

SAFETY
Marking “Ex p” II 2G,
standard IEC 60079-2, zone 1, 2 Marking “Ex e” II 2G,
Marking “Ex pD” II 2D, standard IEC 60079-7, zone 1, 2 2
standard IEC 61241-4, zone 21,22

Principle Principle
The ‘Ex p’ type of protection, protection by pressurized The ‘Ex e’ protection applies to the electrical equipment
apparatus, consists in introducing an ignition shield gas into which does not produce arcs, sparks or hazardous
the enclosure in order to keep it at a pressure above that of temperatures under normal operation (non-sparking
the external atmosphere, thus preventing the formation of an constructions).
explosive atmosphere inside the enclosure itself. Additional protection measures are applied, in order to
The shield gas may be composed of air or inert gas, such as provide increased safety with a higher safety coefficient,
nitrogen; if the overpressure fails, the control unit causes the which must prevent the formation of arcs or sparks or the
alarm or shutdown of the pressurized equipment. possibility of temperatures that could ignite the explosive
The internal overpressure technique may also be applied, mixture; this objective is based on a general oversizing of
essentially with the same characteristics, to the equipment both insulating materials and the active electrical parts with
for dust by applying the specific standard; in this case the respect to electrical constructions of normal industrial
marking is ‘Ex pD’. production, which are already non-initiating in themselves.
Applications Applications
MV/LV transformers, large electrical machinery (as an Plant-engineering materials such as enclosures with
alternative to the ‘Ex e’ protection), automation and terminals, electromagnets and coils, motors and generators,
instrumentation panels, industrial process control systems lamps, batteries, electric resistance heaters, current
(chromatograph gases, analyzers), analysis booths and transformers, voltage transformers.
pressurized rooms.

9
Guide to the ATEX directives

PROTECTION EX n NON-SPARKING EQUIPMENT

Marking “Ex nA” II 3G
Standard IEC 60079-15, zone 2 Principle
The “n” type of protection actually This principle applies to the “non-sparking” equipment, i.e.,
represents a group of protection equipment which does not produce arcs, sparks or
types: containment, segregation hazardous temperatures under normal operation.
and prevention, each capable of Applications
preventing ignition of the explosive atmosphere, during Motors, fuses, lamps, low-power equipment and instruments,
normal operation only. current transformers, plant-engineering materials such as
The protection Ex n is only applicable for zone 2, category terminal boxes, junction boxes and socket-outlets.
3 G; in zone 2 the probability of the presence of an explosive
atmosphere is very low (= 10 h/year) and thus the level of RESTRICTED BREATHING ENCLOSURES
protection required is lower than that of the components for Marking “Ex nR” II 3G
zone 0 and 1 (category 1 and 2). Principle
The ‘Ex n’ protection includes the protection methods which The restricted breathing technique is designed to reduce the
are “simplified”, but not simple in terms of technical / regulatory possibility of the ingress of a surrounding explosive atmosphere
requirements, each of which is applied preferably to some to a low level, in other words to guarantee that the concentration
types of equipment. of flammable gas inside the enclosure does not exceed the
The standard considers both the general requirements lower explosive limit of the gas, for the period of time in which
(metal and plastic materials, mechanical strength and the gas is present in the external atmosphere. The ‘Ex nR’
insulation, distance, earthing, IP) applicable to all the enclosures are designed and built so as to limit the ingress of
equipment, as well as the specific requirements for the type gas; the tests are carried out by creating a pressure
of protection. difference between the interior and exterior of the enclosure
The equipment is divided into “non-sparking” equipment and verifying that the leaks are less that the predetermined
and “sparking” equipment, i.e., equipment which produces value over a certain time. The equipment installed inside the
arcs, sparks or high surface temperatures under normal ‘Ex nR’ enclosures must also have reduced heat dissipation so
operation. that the internal temperature does not exceed the exterior
An example of non-sparking equipment would be motors ambient temperature by 10°C or more. The restricted
and lamps, which have requirements similar to that provided breathing enclosures must be equipped with a test connector
for by the ‘Ex e’ increased safety protection. The sparking that allows the breathing properties to be checked and
equipment category includes other protection techniques maintained during normal operation, even after installation
such as the “restricted breathing enclosures”, the “closed- and maintenance activities.
cell devices” and the “hermetically sealed devices”; in Applications
summary, we can have: This type of protection applies to “sparking” equipment, i.e.,
Ex nA: non-sparking equipment; equipment which produces arcs or sparks or hot points
Ex nC: sparking equipment; during normal operation (switches, contactors, relays,
Ex nR: restricted breathing enclosures. measuring instruments, lamps).

ENCAPSULATION to the environmental factors, particularly the electrical,

thermal, mechanical and chemical factors, is achieved by
Marking “Ex m” II 2G, standard means of resin.
IEC 60079-18, zone 0, 1, 2 The ‘Ex mb’ equipment is suited for zone 1, while the ‘Ex ma’
Marking “Ex mD” II 2D, standard protection is also applicable in zone 0.
IEC 61241-18, zone 20, 21, 22 The ‘Ex mD’ type of protection is based on encapsulation
which is sealed to the penetration of dust and limits the
Principle surface temperature.
In the ‘Ex m’ type of protection the electrical equipment, or
its components, that could ignite an explosive atmosphere Applications
by means of sparks or heat are “segregated” (encapsulated) The ‘Ex m’ protection can be applied to fuses, condensers,
so that the explosive atmosphere cannot be ignited. The windings, transformers, solenoid valves, sensors and
encapsulation of components which are particularly subject electronic devices in general.

10
 INTRINSIC SAFETY For intrinsic safety equipment there are 3 levels of protection
provided, depending on the constructional characteristics
Marking “Ex i” II 2G, standard IEC provided for by the standard:

Guide to the ATEX directives

60079-11, zone 0, 1, 2 Ex ia: applicable in zone 0;
Marking “Ex iD” II 2D, standard Ex ib: applicable in zone 1;
IEC 61241-11, zone 20, 21, 22 Ex ic: applicable in zone 2.
The ‘Ex iD’ type of protection is analogous to the ‘Ex i’
Principle protection provided for explosive atmospheres with gases.
The intrinsic safety uses the principle of energy limitation. The level of energy must be that corresponding to the group
In a circuit with intrinsic safety there are no sparks or thermal IIB. Recall that the ignition energy of gases is less than the
effects, under normal operating conditions and the failure ignition energy of dusts.
conditions specified by the standards, that are capable of
igniting a given explosive mixture, based on the gas group Applications
(IIA, IIB and IIC); this is possible if the characteristics of the The intrinsic safety applies to measurement, control and
circuit and its components are such as to limit the energy regulation instrumentation useable in industrial processes,
accumulated and released by the circuit itself. telecommunications systems and portable equipment.

11
Guide to the ATEX directives

> 4. ATEX DIRECTIVE 99/92/EC: WORKPLACE

REFERENCE LAWS of areas where combustible dusts are or may be present.

a. ATEX Directive 99/92/EC: Minimum requirements to Guide CEI 31-56 Electrical apparatus for explosive dust
improve the safety and health of the workers potentially at atmosphere. Guide for the “Classification of areas where
risk of explosive atmospheres. combustible dusts are or may be present”.
b.Guidelines for the application of the ATEX Directive 99/92/EC.
c. Lgs.D. 81/2008 of 9 April 2008 – Title XI: Protection from IEC 60079-31 Equipment dust ignition protection by
explosive atmosphere. enclosure “t”. This Standard applies to electrical equipment
d.Lgs.D. 106/2009 of 3 August 2009 – Supplementary and protected by means of enclosures and with surface
corrective provisions to Lgs.D. 81/2008, on health and temperature limitation, intended for use in an explosive dust
safety in the workplace. atmosphere.

In concordance with the requirements of law, the INSTALLATIONS AND MAINTENANCE

assessment of the explosion risk (classification of the IEC EN 61241-14**** (CEI 31-67) Electrical apparatus for
areas, explosion protection document, selection of the use in the presence of combustible dust. Part 14: Selection
installations and respective equipment) must be carried and installation.
out by personnel with specific expertise in the area. IEC EN 61241-17 (CEI 31-67) Electrical apparatus for use in
the presence of combustible dust. Part 17: Electrical
REFERENCE STANDARDS installations inspection and maintenance in areas with risk of
The primary reference standards concerning the explosion explosion (other than mines).
hazard areas are provided below, subdivided for gas or Note: Always check the validity of the current standards
dust; for installations with the presence of both gas and on the site: http://www.ceiweb.it
dust, the cited standards apply jointly.
Classification of areas
AREAS WITH THE PRESENCE OF GAS This classification has the purpose of identifying the areas
Classification where there is the possibility for a potentially explosive
IEC EN 60079-10* (CEI 31-30) Electrical apparatus for atmosphere to form, so as to enable the proper selection
explosive gas atmosphere. Part 10: Classification of hazardous and installation of equipment suited for the environment
areas. (hazardous area).
Guide CEI 31-35 Electrical apparatus for explosive gas The definition of the different areas, within a location with risk
atmosphere. Guide to the application of the standard IEC of explosion, represents a significantly complex design
EN 60079-10 (CEI 31-30). Classification of areas with problem which requires specific knowledge. On a regulatory
explosion hazard due to the presence of flammable gas, level, the areas where the risk of explosion is due to the
vapours or mists. presence of gas and those where it is due to the presence
of dust are handled separately; this is the result of the
INSTALLATIONS AND MAINTENANCE different behaviour of the gases with respect to the dusts in
IEC EN 60079-14** (CEI 31-33) Electrical apparatus for terms of the explosion risks.
explosive gas atmosphere. Part 14: Electrical installations in • Zones with the presence of gas
areas with explosion hazard due to the presence of gas The definition of the areas with risk of explosion due to the
(other than mines). presence of gas is made based on the frequency and
IEC EN 60079-17 (CEI 31-34) Electrical apparatus for duration of the presence of explosive atmosphere; the
explosive gas atmosphere. Part 17: Electrical installations standard identifies three different zones:
inspection and maintenance in areas with risk of explosion • Zone 0: a place in which an explosive gas atmosphere is
due to the presence of gas (other than mines). present continuously or for long periods.
• Zone 1: a place in which an explosive atmosphere is likely
AREAS WITH THE PRESENCE OF DUST to occur during normal operation.
Classification • Zone 2: a place in which an explosive atmosphere is not
IEC EN 61241-10*** (CEI 31-66) Electrical apparatus for use likely to occur during normal operation, but if it does occur,
in the presence of combustible dust. Part 10: Classification it will persist for a short period only.

* Will be replaced by the standard IEC/EN 60079-10-1 (gas). *** Will be replaced by the standard IEC/EN 60079-10-2 (dust).
** As of 1.07.2011, will be replaced by the standard IEC/EN 60079-14 ****As of 1.07.2011, will be replaced by the standard IEC/EN 60079-14
(gas and dust). (gas and dust).

12
SOME DEFINITIONS lower explosive limit (LEL) almost immediately.
Lower explosive limit (LEL) • Medium ventilation (MV): when the ventilation is able to
Concentration of a flammable gas or vapour above which an affect the concentration of gas in a stable manner, lowering

Guide to the ATEX directives

atmosphere becomes explosive. the concentration below the LEL or where the hazardous
Upper explosive limit (UEL) atmosphere persists for a short period.
Concentration of a flammable gas or vapour above which an • Low ventilation (LV): when the ventilation is unable to
atmosphere is no longer explosive. affect the concentration of gas in a stable manner and is
Emission source (ES) incapable of persistently limiting a hazardous atmosphere.
A point or a part of the installation from which it is possible In addition to the degree of ventilation, the efficiency of a
to have the emission of a gas, liquid or vapour which could ventilation system also depends on its availability; the
create a potentially explosive atmosphere. presence of high ventilation (HV) may be thwarted by its
scarce availability (e.g., a faulty fan).
DEGREE OF EMISSION With regard to the availability, we have the following
The degree of emission represents the probability that an definitions:
emission source emits gas, liquid or vapour such as to • Good ventilation: when the ventilation is present continuously.
create a potentially explosive atmosphere. • Adequate ventilation: when the ventilation is present
• Continuous emission: continuous emission or emission during normal operation; infrequent interruptions for short
for long periods. periods are allowed.
• Primary emission: periodic or occasional emission during • Poor ventilation: when the ventilation is not able to meet
normal operation. the requirements in order to be considered good or
• Secondary emission: emission which is unlikely during adequate; in any case no long-lasting interruptions are
normal operation or which occurs only rarely or for short expected.
periods.
The type of zone is strictly related to the degree of emission; GAS CLASSIFICATION CRITERIA
in general, a continuous emission generates a zone 0, a The classification of the areas with risk of explosion is a
primary emission generates a zone 1 and secondary rather complex procedure, but it is essentially based on the
emission generates a zone 2. identification of the following elements:
The ventilation is the element that can change this • Number and position of the emission sources (ES)
correspondence, as poor ventilation or lack of ventilation • Type of emission sources: degree, emission flow rate.
could aggravate the classification of the zone (e.g., a • Degree of ventilation: high (HV), medium (MV), low (LV).
primary emission could then lead to a zone 0 instead of a • Availability of ventilation: good, adequate or poor.
zone 1). The elements cited above lead, by means of calculations
and other assessments, to the definition of the hazardous
VENTILATION zones and relative extensions; generally the hazardous
Movement of the air or its replacement with fresh air produced zones are represented on the installation designs using the
by the wind, a thermal gradient or artificial means (fans or graphic symbols shown below.
extractor units).
The gases or vapours which can create an explosive
atmosphere can be diluted in the air, thereby dropping
below the minimum hazard levels; thus efficient ventilation
allows to obtain a reduction of the hazardous zone. The
ventilation can be distinguished based on its efficiency and Zone 0 Zone 1 Zone 2
availability. Although there is no fixed rule regarding the presence
The following degrees of ventilation have been identified: (duration and probability) of explosive atmosphere in
• High ventilation (HV): when the ventilation is able to relation to the zones (0, 1, 2), the following table represents
reduce the concentration of hazardous gas below the a useful reference.

Zone Probability of explosive Overall duration of explosive atmosphere

atmosphere
Zone 0 P > 10-1 > 1000 h / year
Zone 1 10 > P > 10
-1 -3
from 10 to 1000 h / year
Zone 2 10-3 > P > 10-5 < 10 h / year

N.B.: In order to apply this rule, however, suitable and reliable statistical data must be available.

13
Guide to the ATEX directives

SOME EXAMPLES OF POSSIBLE HAZARDOUS ZONE SITUATIONS FOR GAS AND VAPOURS

Zone Examples

Surfaces of a flammable liquid exposed directly to the atmosphere.

0
Continuous free venting of flammable substance.

Opening for filling with a flammable liquid.

1
Single mechanical seal.

Connection flange.
2
Pool of flammable liquid which may form infrequently or for short periods.

The points and parts of the installation that may create • the containers of flammable substances with tightly closed covers;
explosive atmospheres only due to catastrophic failures are • the disabled parts of the installation, in which the flow of
not considered to be emission sources: flammable substances is prevented by means of valves or
• the welded piping and containers welded up to standard; similar devices.

ZONE 0 ZONE 1 ZONE 2 ZONE 2 Example of a plan with hazardous

zones caused by emission
sources.

SUITABLE ELECTRICAL EQUIPMENT

The electrical equipment installed in the zones classified for be suitable for the hazardous zones as shown in the table
gas must conform to the ATEX Directive 94/9/EC and must below:

Hazardous zone Directive 94/9/EC category

Gas and vapours Zone 0 1G

Gas and vapours Zone 1 2G or 1G
Gas and vapours Zone 2 3G or 2G or 1G

14
ZONES WITH THE PRESENCE OF DUST • Zone 22: a place in which an explosive atmosphere under
The classification of the areas with risk of explosion due to the form of combustible dust in the air is not likely to occur
the presence of dust is made in a manner similar to that under normal operation but, if it does occur, it will persist

Guide to the ATEX directives

provided for gas, based on the probability of the presence for only a short period of time.
of an explosive atmosphere.
Dust classification
The standard IEC EN 61241-10 defines three zones: Graphic symbols of the classified zones for dusts:
• Zone 20: a place in which an explosive atmosphere under
the form of combustible dust in the air is present continuously,
frequently or for long periods.
• Zone 21: a place in which an explosive atmosphere under
the form of combustible dust in the air is likely to occur
under normal operation occasionally. Zone 20 Zone 21 Zone 22

SOME EXAMPLES OF POSSIBLE HAZARDOUS ZONE SITUATIONS FOR DUSTS

Zone Examples

Filters, cyclones.
20
Dust transport systems, interiors of mixers, mills, dryers, desiccators.

Zones outside hoppers.

21
Areas near filling and emptying points.

Dust transport systems, interiors of mixers, mills, dryers, desiccators.

22
Areas near equipment that is opened occasionally.

SOME DEFINITIONS Dust classification criteria

Combustible dusts The classification for dusts is also a complex procedure that
Dust capable of burning in air and forming explosive mixtures requires the identification of the type, the number and
with air at atmospheric pressure and normal temperatures. degree of the emission sources. Occasionally, depending
Dust containment on the installation conditions, the introduction of ventilation
Parts of the process equipment within which the dust is may allow some areas to be classified as zone 22 which
handled, treated, transported or stored, e.g., to prevent the would otherwise be considered as zone 21.
emission of dust into the surrounding atmosphere. Suitable electrical equipment
Date emission source The electrical equipment installed in the classified zones
Point or place from which the combustible dust may be must conform to the ATEX Directive 94/9/EC and must be
emitted into the atmosphere. suitable for the hazardous zones as shown in the table below:

Hazardous zone Directive 94/9/EC category

Dusts Zone 20 1D

Dusts Zone 21 2D or 1D

Dusts Zone 22 3D or 2D or 1D

15
Guide to the ATEX directives

> 5. EQUIPMENT SELECTION

The equipment must be selected based on the hazardous Hazardous zone

zone, the substances present, the ignition temperatures The selection must be made considering the equipment
and the environmental characteristics of the installation category (ATEX 94/9/EC) which must be SUITABLE for the
locations. type of zone (ATEX 99/92/EC).

Hazardous zone Directive 94/9/EC category

Gas and vapours Zone 0 1G

Gas and vapours Zone 1 2G or 1G

Gas and vapours Zone 2 3G or 2G or 1G

Dusts Zone 20 1D

Dusts Zone 21 2D or 1D

Dusts Zone 22 3D or 2D or 1D

SUBSTANCES also be used, for safety, in the locations where equipment of

The various substances have different explosive behaviours. a less restrictive group is suitable. In other terms:
The group II electrical equipment, for gas and vapours, is • an apparatus of the group IIB can be used in places which
divided into subgroups IIA, IIB and IIC in relation to the require an apparatus of the group IIA;
substance, where the group IIC is the most restrictive • an apparatus of the group IIC can be used in places which
and the group IIA is the least restrictive. Based on the require an apparatus of the groups IIA and IIB.
substance, it is possible to identify the group to which the Occasionally, an apparatus is indicated as suitable for a gas
equipment must belong (see Annex GA of the guide CEI group (IIB for example) and for a certain gas of the
31-35, or the publication IEC/EN 60079-20-1). subsequent group, hydrogen for example; in this case the
The electrical equipment certified for a certain gas group can apparatus is marked as IIB + H².

IGNITION TEMPERATURE Equipment for gas

The selection of the equipment based on the ignition tem- The surface temperature of the electrical equipment must
perature of the substances is one of the fundamental not exceed the ignition temperature of the hazardous sub-
aspects for guaranteeing the safety of installations against stances present; for group II electrical equipment the maxi-
the risk of explosion. mum surface temperatures are divided into temperature
The selection criteria is different depending on whether the classes from T1 to T6 according to the limits indicated in the
equipment is intended for gas or dust. table below.

Maximum surface temperature Ignition temperature

Temperature class
of the equipment of the flammable substance

T1 450°C >450°C

T2 300°C >300°C

T3 200°C >200°C

T4 135°C >135°C

T5 100°C >100°C

T6 85°C >85°C

16
The equipment certified for a certain temperature class can For example:
also be used, for safety, in the locations where a class with • a T3 apparatus can be used in places which require T1 and T2;
higher maximum surface temperature is allowed. • a T6 apparatus can be used in all the hazardous areas.

Guide to the ATEX directives

THE TABLE BELOW PROVIDES THE CLASSIFICATION (GROUP AND TEMPERATURE CLASS) OF SOME SUBSTANCES
COMMONLY FOUND IN INDUSTRIAL INSTALLATIONS:

Gas/Vapour Group Temperature class

Acetic Acid IIA T1

Acetone IIA T1

Acetylene IIC T2

Ammonia IIA T1

Butane IIA T2

Cyclohexane IIA T3

Ethanol (ethyl alcohol) IIA T2

Ethylene IIB T2

Hydrogen IIC T1

Kerosene IIA T3

Methane (natural gas) IIA T1

Methanol (methyl alcohol) IIA T2

Methyl Ethyl Ketone (MEK) IIB T2

Propane IIA T1

Propanol (isopropyl alcohol) IIA T2

Tetrahydrofuran (THF) IIB T3

Toluene IIA T1

Xylene IIA T1

EQUIPMENT FOR DUST areas).

In order to prevent the electrical equipment from igniting a For each type of dust, the minimum ignition temperature is
dust cloud with ignition temperature Tcl it is sufficient, in defined for a layer with a thickness of 5 mm T5mm.
theory, that the maximum surface temperature (T) of the The maximum temperature (Tmax l) to prevent the ignition of
equipment does not exceed Tcl; in practice, the standard the dust layers must be 75 K (safety margin) less than the
introduces a safety coefficient and assumes a maximum minimum ignition temperature of the 5mm-thick layer.
temperature Tmax cl = (2/3) Tcl Thus: Tmax l = T5mm – 75
Thus the equipment must have a maximum surface The maximum surface temperature (T) of the equipment must
temperature (T) = Tmax cl = (2/3) Tcl not exceed the lower value of the two temperatures Tmax cl =
If dust layers may form in the area in question, it is (2/3) Tcl and Tmax l = T5mm - 75
necessary to prevent the electrical equipment from igniting
the dust layer; for this purpose, the surface temperature of
the equipment must be limited in relation to the thickness of
the dust layer (generally indicated in the classification of the

17
Guide to the ATEX directives

An example of determining the maximum permissible surface

temperature of an electrical apparatus in the presence of flour:
Tcl = minimum ignition temperature in cloud = 380°C
Tmax cl = (2/3) Tcl = 253°C
T5mm = minimum ignition temperature in layer = 300°C
Tmax l = T5mm - 75 = 225°C
• Minimum value between Tmax cl (253°C) and Tmax l (225°C) = 225°C
• Maximum surface temperature of the apparatus = 225°C
The determination is more complicated if the thickness of
the layer exceeds 5 mm (up to 50 mm); in this case the Tmax l
is obtained from the curves shown in the figure.
If the layer is thicker than 50 mm, a specialized laboratory
must determine the value of Tmax l.

THE TABLE BELOW PROVIDES THE IGNITION TEMPERATURE DATA (CLOUD AND LAYER) FOR SOME FLAMMABLE DUSTS

Typical ignition temperature (°C)

Dust
Cloud Layer
Aluminium 560 450
Ground Coal 420 230
Cellulose 520 410
Flour 380 320
Synthetic Rubber 450 220
Wood 410 220
Methyl Cellulose 420 320
Phenolic Resin 530 >450
Polyethylene 420 melts
PVC 700 >450
Toner 530 melts
Starch 460 435
Sugar 490 460

AMBIENT TEMPERATURE
The ambient temperature range for use of the ATEX must be specified directly on the plate or by reporting the
equipment, for both gas and dust, is usually between -20°C symbol X on the plate and providing the temperature range
and +40°C, unless specified otherwise. in the instructions for use.
For values different from the range -20°C / +40°C, the indication The following conditions are provided for:

Equipment plate Conditions to be observed

No indication -20°C ≤ T ambient ≤ + 40°C
Temperature range or X and temperature range specified minimum T ambient MINIMUM Ta declared
in the instructions for use maximum T ambient ≤ MAXIMUM Ta declared

18
> 6. EVOLUTION OF DUST STANDARDS

EQUIPMENT PROTECTION LEVEL EPL

Guide to the ATEX directives

The ATEX Directive 94/9/CE defines the categories 1,2,3
(group II) based on the level of protection. The standard
EN/IEC 60079-0 (Ed.5) introduces the concept of EPL
(Equipment protection level).

ATEX CATEGORIES AND EPL

Explosive atmosphere Zone ATEX Category EPL

0 1G Ga

GAS 1 1G or 2G Ga or Gb

2 1G or 2G or 3G Ga or Gb or Gc

20 1D Da

Dusts 21 1D or 2D Da or Db

22 1D or 2D or 3D Da or Db or Dc

Table 1

EVOLUTION OF DUST
The standard EN/IEC 60079-0 (Ed.5) introduces group III
regarding equipment for dusts. The dusts are divided into 3
subgroups: (IIIA, IIIB, IIIC).

Group Hazardous substances

IIIA Combustible volatile substances (fibres)

IIIB Non-conductive dusts

IIIC Conductive dusts

19
Guide to the ATEX directives

EXAMPLE OF NEW MARKING ACCORDING TO THE STANDARD EN/IEC 60079-0 (ED.5)

1 3 5

2 4 6

Ex e ia IIC T6 Gb (Ta -xx°C +xx°C)

Ex t IIIC IP66 T85°C Db (Ta -xx°C +xx°C)

7 9 10 11 12

GAS PROTECTION DUST PROTECTION

1 - Ex: Conforms to the Harmonized European standards 7 - Ex: Conforms to the Harmonized European standards
2 - e: Type of protection applied (increased safety) 8 - t: Protection by enclosure
3 - ia: Intrinsic safety 9 - IIIC: Conductive dusts
4 - IIC: Gas Group 10 - IP66: Degree of protection
5 - T6: T6 = 85°C – temperature class 11 -T85°C: Maximum permissible surface temperature of
6 - Gb: Zone 1 Gas (see Table 1) the electrical apparatus
12 - Db: Zone 21 Dusts (see Table 1)

> 7. APPLICATION EXAMPLES

The list below provides some examples of general and - CAR REPAIR SHOPS
particular situations associated with the possibility of - FUEL FILLING STATIONS
forming an explosive atmosphere (hazardous zones) and - PAINT BOOTHS (LIQUID)
relative characteristics of the installations. - PAINT BOOTHS (POWDERS)
- CHEMICAL / PETROCHEMICAL / PHARMACEUTICAL - WOODWORKING AND FURNITURE INDUSTRIES
INDUSTRIES - GRAIN STORES
- GAS HEATING PLANTS - BAKERIES AND PASTRY SHOPS
- GARAGES

20
> CHEMICAL / PETROCHEMICAL / PHARMACEUTICAL INDUSTRIES

Guide to the ATEX directives

> GENERAL INFORMATION > PRIMARY REFERENCE LAWS AND STANDARDS
The chemical, petrochemical and pharmaceutical industries The primary reference laws and standards are cited in the
constitute the majority of installations with potentially previous paragraphs.
explosive atmospheres due to the presence of flammable
liquids, gas/vapours and/or dusts. > CHARACTERISTICS OF THE INSTALLATIONS
The type of zone, its shape and dimensions are determined
> HAZARDOUS SUBSTANCES by applying the cited standards and depend essentially on
Considering the substantial variability of the substances which certain variables such as: ventilation, substance, type and
may be present, a specific assessment of the substances and degree of the emission source, containment system, etc.
their characteristics is required in order to determine the explosion The electrical equipment must conform to the ATEX
risk. If there is no data on the substances available in the Directive 94/9/EC and must be suitable for the hazardous
literature (standards, guides, safety data sheets, etc.), laboratory zones as summarized in the table below:
tests must be carried out in order to characterize the substances.

Hazardous zone Directive 94/9/EC category

Gas and vapours Zone 0 1G

Gas and vapours Zone 1 2G or 1G

Gas and vapours Zone 2 3G or 2G or 1G

Dusts Zone 20 1D

Dusts Zone 21 2D or 1D

Dusts Zone 22 3D or 2D or 1D

21
Guide to the ATEX directives

> GAS HEATING PLANTS

> GENERAL INFORMATION DPR 661/96 and the regulations consider these devices to
This example considers the rooms or group of rooms, if be intrinsically safe, not entailing any risk of leaks and thus
directly communicating with one another, in which a heating explosion; these areas are to be considered as “ordinary”. In
plant with a power greater than 35 kW (30000 kcal/h) is installed. the second case the plants do not use devices compliant
The risk of explosion is related to the presence of the gas with DPR 661/96; this category includes all the devices
used for combustion which could leak from the installation. which use hot water with water temperature above 105°C or
are used in an industrial process.
> INSTALLATION CHARACTERISTICS The fundamental difference with respect to the previous
For a proper electrical installation, two distinct cases must situation is that in this case the risk of explosion induced by
be considered: the equipment cannot be excluded a priori. The guide CEI
1. Equipment which use devices that are compliant with DPR 31-35 applies to methane heating plants provided that:
661/96. - the relative operating pressure is not above 4000 Pa
2. Equipment which use devices that are non-compliant with - the emission sources would have an emission hole, due to
DPR 661/96. failure, no larger than 0.25 mm2
In the first case, the heating plant uses gas equipment which The guide CEI 31-35 allows to exclude the risk of explosion
has the CE marking according to Directive 90/396/EC (DPR if the openings have a free area (in m2) of:
661/96). - 0.3 m2, heating plants with a nominal operating pressure of
Art. 1 of the DPR identifies the equipment that falls within the up to 2000 Pa.
scope of application; this equipment includes all the devices - 0.5 m2, heating plants with a nominal operating pressure of
using gaseous fuel and, if applicable, water with normal up to 4000 Pa.
temperature less than 105°C, used for: Cooking – Heating, These openings will have to be located in the highest part of
production of hot water - Cooling - Lighting. the outer walls of the building.

> HAZARDOUS SUBSTANCES

Flash Specific Ignition Group and

Name Composition LEL % UEL %
temperature °C gravity temperature °C temperature class
Methane CH <0 4.4 17.0 0.55 537 IIAT1
LPG CxHx <0 2.0 9.0 >1.50 365 (IIB)T2
Among the gases used, natural gas (methane) is lightweight, with specific gravity < 0.8, while LPG is heavy, with specific gravity of > 1.2.

22
> GARAGES

Guide to the ATEX directives

> GENERAL INFORMATION system (natural and/or artificial).
This example considers parking garages intended to house c. The motor vehicles are normally parked with the motor
more than nine vehicles. The risk of explosion is related to switched off and the starter motor disconnected.
the possible leakage of the fuel contained in the vehicles. d.No other flammable substances are present, other than
The parking of LPG-powered vehicles, with an installation the fuel contained in the motor vehicles.
equipped with safety devices compliant with current e. The tanks are not filled or emptied on site.
legislation, is allowed on the floors above ground and the f. Access is denied to motor vehicles with visible fuel leaks;
first underground floor of the garages (DM 21/11/2002). if necessary, intervene immediately with suitable means of
neutralization.
> INSTALLATION CHARACTERISTICS g.The motor vehicles are homologated and maintained in
In light of that provided for by the guide CEI 31-35, the good working order (overhauled).
garages are not to be considered as areas with risk of The classification of the areas is necessary only in the case
explosion if the following requirements are met: in which one or more of the cited requirements are not met.
a. The fuels used are: petrol, liquefied petroleum gas (LPG), The equipment installed inside the garage must be
compressed natural gas (CNG); the fuels must not be protected from mechanical impacts caused by the
heated or atomized. movement of the motor vehicles themselves; in particular,
b. The regulations of DM 1 February 1986 must be implemented, the socket-outlets must be installed at a height of 1.15
with particular reference to the efficiency of the ventilation meters above the floor.

> HAZARDOUS SUBSTANCES

Flash Specific Ignition Group and

Name Composition LEL % UEL %
temperature °C gravity temperature °C temperature class

Petrol - <0 0.70 5.9 ≥ 2.50 280 IIAT3

Methane CH4 <0 4.4 17.0 0.55 537 IIAT1

LPG CxHx <0 2.0 9.0 >1.50 365 (IIB)T2

23
Guide to the ATEX directives

> CAR REPAIR SHOPS

> GENERAL INFORMATION the fuel contained in the motor vehicles.

This example considers the car repair shops where repair work e. The tanks are not filled or emptied on site.
and maintenance operations are carried out on motor vehicles. f. Access is denied to motor vehicles with visible fuel leaks;
in necessary, intervene immediately with suitable means
> INSTALLATION CHARACTERISTICS of neutralization.
In light of that provided for by the guide CEI 31-35, the car g.The motor vehicles are homologated and maintained in
repair shops are not to be considered as areas with risk of good working order (overhauled).
explosion if the following requirements are met: h. No work is carried out on the carburetor circuits.
a. The fuels used are: petrol, liquefied petroleum gas (LPG), i. If there are any work pits in the car repair shop, it must
compressed natural gas (CNG); the fuels must not be have an artificial ventilation system with air extraction (at
heated or atomized. least 50 exchanges / hour).
b. The regulations of DM 1 February 1986 must be implemented, The classification of the areas is necessary only in the case
with particular reference to the efficiency of the ventilation in which one or more of the cited requirements are not met.
system (natural and/or artificial). The equipment installed inside the car repair shops must be
c. The motor vehicles are normally parked with the motor protected from mechanical impacts caused by the motor
switched off and the starter motor disconnected. vehicles themselves; in particular, the socket-outlets must
d.No other flammable substances are present, other than be installed at a height of 1.50 meters above the floor.

> HAZARDOUS SUBSTANCES

Flash Specific Ignition Group and

Name Composition LEL % UEL %
temperature °C gravity temperature °C temperature class

Petrol - <0 0.70 5.9 ≥ 2.50 280 IIAT3

Methane CH4 <0 4.4 17.0 0.55 537 IIAT1

LPG CxHx <0 2.0 9.0 >1.50 365 (IIB)T2

24
> FUEL FILLING STATIONS

Guide to the ATEX directives

> GENERAL INFORMATION Zone 2
This example considers the areas where filling stations are - Zone for positioning the pump nozzle outside zone 1, for a
installed for the refuelling of motor vehicles. horizontal extension of 20 cm.
- Venting zone of the installation outside zone 1, for a horizontal
> INSTALLATION CHARACTERISTICS extension of 20 cm.
An example of the hazardous zones of a filling station is - Zone above the cover of the tank filling trap for a horizontal
provided below. extension of 20 cm and vertical extension of 10 cm beyond
Zone 1 the perimeter of the trap.
- Volumes inside the filling column. - Vent of the balance pipes of the underground tanks within
- Zone for positioning the pump nozzle downwards to the an area with a radius of 75 cm.
ground and horizontally for 10 cm. In any case, recall that these environments must be classified
- Venting zone of the installation downwards to the ground in concordance with that defined by the standard EN 60079-10.
and horizontally for 10 cm.
- Volume inside the filling trap of the tank.

> HAZARDOUS SUBSTANCES

Flash Specific Ignition Group and

Name Composition LEL % UEL %
temperature °C gravity temperature °C temperature class

Petrol - <0 0.70 5.9 ≥ 2.50 280 IIAT3

Methane CH4 <0 4.4 17.0 0.55 537 IIAT1

LPG CxHx <0 2.0 9.0 >1.50 365 (IIB)T2

25
Guide to the ATEX directives

> PAINT BOOTHS (LIQUID)

> GENERAL INFORMATION • Concentration within 25% of the LEL (booths with operator
This example considers the environments in which spray presence).
painting is carried out with liquid paints containing flammable Zone 2: the volume inside the booth (including the air
solvents capable of forming an explosive atmosphere. recirculation ducts) and the volume outside the booth up to
1m from the permanent openings.
> INSTALLATION CHARACTERISTICS
Paint booths have demanding conditions concerning the • Concentration within 50% of the LEL (booths without operator
exposure to explosive atmospheres. presence).
The standard UNI EN 12215 “Spray booths for application of The booth must be equipped with an LEL control system
organic liquid coating materials – Safety requirements” that blocks the flow of flammable substances upon reaching
specifies the protective measures to adopt in order to 50% of the LEL.
prevent the risks of explosion. Zone 1: the volume inside the booth (including the air
The standard requires that the concentration of flammable recirculation ducts).
substances be kept below the LEL by means of forced Zone 2: the volume outside the booth up to 1m from the
ventilation. In particular, 2 situations are provided for: permanent openings.

> HAZARDOUS SUBSTANCES

Flash Specific Ignition Group and

Name Composition LEL % UEL %
temperature °C gravity temperature °C temperature class

Acetone C3COCH3 <0 2.5 13.0 2.0 465 IIAT1

Toluene C6 H5CH3 4 1.1 7.1 3.2 480 IIAT1

Xylene C6 H4(CH3)2 17 1.1 6.4 3.6 464 IIAT1

26
> PAINT BOOTHS (POWDERS)

Guide to the ATEX directives

> GENERAL INFORMATION In particular, the following classification is provided for:
This example considers the environments in which spray • Zone 22: the volume inside the booth (including the air
painting is carried out with powder coatings capable of recirculation ducts and the open powder recovery systems);
forming an explosive atmosphere. • Zone 22: the volume outside the booth up to 1m from the
permanent openings;
> INSTALLATION CHARACTERISTICS • Zone 20: the closed powder recovery systems.
The standard UNI EN 12981 “Spray booths for application of
organic powder coating materials – Safety requirements” > HAZARDOUS SUBSTANCES
specifies the protective measures to adopt in order to The characteristics of the powders used are quite variable
prevent the risks of explosion. The standard requires that the and depend highly on the type of product used.
concentration of flammable substances be kept below the Indicatively, the LEL is between 10÷100 g/m3, while the
50% of the LEL of the dusts, by means of forced ventilation; ignition temperatures vary between 350÷400°C (cloud) and
if the value of the LEL is unreliable, the average concentration 200÷250°C (layer); it is recommended that you always
must not exceed 10 g/m3. check the data on the product safety data sheets.

27
Guide to the ATEX directives

> WOODWORKING AND FURNITURE INDUSTRIES

> GENERAL INFORMATION and are more hazardous; these dusts, however, are removed
This example considers the areas used for woodworking by the aspiration systems.
(cutting, milling, planing, etc.) with machines provided with The hazard of wood dust is marked by its low ignition
aspiration systems to remove sawdust and wood dusts. temperature in layer form; thus in order to limit this risk,
thorough cleaning procedures are recommended to prevent
> INSTALLATION CHARACTERISTICS the formation of layers.
Shavings, sawdust and wood dusts are produced in the In general, the classification includes zone 22 with the
furniture and woodworking industries. extension of a few meters around the machines and the
The shavings and sawdust usually remain suspended in the areas where the dusts may deposit; hazardous zones also
air for brief periods due to their dimensions. exist inside the dust recovery systems (filters) and the ducts
The finer wood dusts remain suspended for a longer time (zone 20 and/or zone 21).

> HAZARDOUS SUBSTANCES

5mm
Cloud ignition Layer ignition Conductivity
Average particle
Substance LEL [g/m3] temperature Tcl [°C] temperature of the dust
size [μm]
T5mm [°C] (C / NC)

Sawdust 63 30 490 310 NC

28
> GRAIN STORES

Guide to the ATEX directives

> GENERAL INFORMATION
This example considers the silos used to store grains (wheat,
corn, rice, soy, flours, etc.) in which loading, unloading and
other processing operations take place which could
generate an explosive atmosphere.

> INSTALLATION CHARACTERISTICS

The grain dusts, due to their low specific weight, can remain
suspended in air for long periods, thus generating explosive
atmospheres. In the grain storage areas, by way of example,
the following classifications are possible:
• Zone 20: volume inside the silos;
• Zone 21: loading and unloading zone (loaders and hoppers)
and adjacent zones;
• Zone 22: volume around the zone 21, with an extension of a
few meters; it also includes the areas in which the dusts may
deposit in layers and the storehouses of packages which
may break.

> HAZARDOUS SUBSTANCES

5mm
Cloud ignition Layer ignition Conductivity
Average particle
Substance LEL [g/m3] temperature Tcl [°C] temperature of the dust
size [μm]
T5mm [°C] (C / NC)

Wheat flour 57 60 430 430 NC

Grain 80 60 370 370 NC

Soy flour 59 125 430 430 NC

29
Guide to the ATEX directives

> BAKERIES AND PASTRY SHOPS

> GENERAL INFORMATION

This example considers the small production businesses,
such as bakeries and pastry shops, where flours are handled
for the production of food products; large food industries are
excluded from this example.

> INSTALLATION CHARACTERISTICS

The classification varies depending on the type of laboratory,
the sizes of the rooms and the ventilation; some examples of
hazardous zones are provided below.
• Zone 20: volume inside the processing machines;
• Zone 21: flour loading and unloading zone;
• Zone 22: possible in the unlikely event of flour sack breakage.

> HAZARDOUS SUBSTANCES

5mm
Cloud ignition Layer ignition Conductivity
Average particle
Substance LEL [g/m3] temperature Tcl [°C] temperature of the dust
size [μm]
T5mm [°C] (C / NC)

Wheat flour 57 60 430 450 NC

Grain 80 60 370 290 NC

Caster sugar
22 60 380 - NC

30
> 8. AMERICAN STANDARDS

In North America the installations in hazardous zones (haz- North American procedure.

Guide to the ATEX directives

ardous locations) are governed by various regulations, such For hazardous areas there are 2 divisions, based on the
as NFPA, NEC, CEC, NEMA, etc. probability that a potentially explosive atmosphere is present.
The National Electrical Code (NEC) is the plant-engineering • Division 1: an explosive atmosphere may be present dur-
standard used in USA for the realization of electrical instal- ing normal operation.
lations in hazardous zones; the Canadian equivalent is the • Division 2: an explosive atmosphere may be present only
Canadian Electrical Code (CEC). in case of failure.
The hazardous locations based on the substances present
are divided into 3 classes:
• Class I – Gas or vapours Gas IEC European North American
Group Group
• Class II – Combustible dusts
• Class III – Flammable fibres, shavings Propane IIA D
Class I substances (gas and vapours) are subdivided into Ethylene IIB C
letters (A, B, C, D); the table below provides the comparison Hydrogen B
Acetylene IIC A
between European/IEC procedure (groups IIA, IIB, IIC) and

DIFFERENCES BETWEEN EUROPEAN AND AMERICAN with the definition of hazardous zones (0, 1, 2) and the
PRACTICE possibility of using products approved according to IEC
The American classification uses the method of Classes and 60079-x standards for the various protection types (Ex-d,
Divisions, unlike the European/IEC procedure that uses the Ex-p, Ex-i, Ex-m, etc.) and equipped with a specific marking.
method of Zones. This means that the products can be approved by:
Generally the European/IEC Zone 2 and the American • Either Class, Division and Substance Group
Division 2 can be considered as equivalent, while the For example: Class 1, Division 2, A,B,C,D T3
American Division 1 includes both Zone 1 and Zone 0; • Or Class, Division and Gas Group
consequently the equipment expressly designed for use in For example: Class 1, Zone 2, IIA, IIB, IIC T3
Zone 1 in Europe cannot always be used in Division 1. The table below indicates the differences between the North
In North America the electrical equipment for hazardous American classification and the European/IEC classification.
locations must be approved for a specified class (Class I, II
or III), for the division (Division 1 or Division 2) and must be
Hazard in
suitable for the substances: gas (A, B, C, D), dusts (E, F, G) Continuous Intermittent abnormal
hazard hazard
and for the temperature (Temperature Code). conditions
Article 505 of the NEC also provides for the possibility of Europe/IEC Zone 0 Zone 1 Zone 2
classification according to the standard IEC 60079-19, i.e., North America Division 1 Division 2

Although Article 505 also allows the use of products equipped

with a marking similar to the European/IEC marking, the
presence of different homologations of the equipment for
zones or divisions is not always acceptable. For example: The
products homologated for Zone 1 do not necessarily meet the
requirements for Division 1, which also includes the Zone 0.
Even though there is no direct equivalence between the ATEX
certifications and the North American certifications, there are
many similarities; recently there is growing recognition of the
IEC types of protection in North America, in light of the IEC EX
certification scheme which is also recognized by North
American countries. Underwriters Laboratory (UL), Factory
Mutual (FM) and Canadian Standard Association (CSA) are
the primary certification bodies in North America.

31
 TECHNOKONTROL ATEX / NFPA ADDITIONAL
ANTI-EXPLOSIVE DATA

PLEASE VIEW THESE WEB LINKS FOR FURTHER ADDITIONAL INFORMATION IN ALL "EXPLOSIVE SECTORS"
WHICH ARE INCORPORATED IN EU ATEX AND NFPA 68/69 2012. SAFETY DIRECTIVES AND GUIDELINES.

-http://www.technokontrol.com/en/products/siaps.php

-http://www.technokontrol.com/en/products/tankers.php

-http://www.technokontrol.com/en/products/psaxss.php

-http://www.technokontrol.com/en/products/valve.php

-http://www.technokontrol.com/en/products/valve-es.php

-http://www.technokontrol.com/en/products/roof.php

-http://www.technokontrol.com/en/products/pipelines.php

-http://www.technokontrol.com/en/products/roof-axspct.php

-http://www.technokontrol.com/en/products/mobile-fuel-tanks.php

-http://www.technokontrol.com/en/products/building-fuel-tanks-es.php

-http://www.technokontrol.com/en/products/building-fuel-tanks-en.php

-http://www.technokontrol.com/en/products/airports.php

IMAGE: PREPARATION/DEGASIFICATION OF A PETROL STATION FUEL TANK , FUEL TANKERS,

STORAGE FACILITIES BEFORE ATEX/NFPA:TK-ANTI-EXPLOSION ALLOYS INSTALLATION.

32
IMAGE: ATEX/NFPA. SAFETY DIRECTIVES FOR ATMOSPHERIC GAS / PETROL-
CHEMICAL RISK-EXPLOSION ZONES

Guide to the ATEX directives

IMAGE:ATEX/NFPA- EXTREME DANGER-DISCHARGING OF EXPLOSIVE GASES/VAPOURS AT
PETROL STATIONS, MANHOLES, STORAGE TANKS

33
TECHNOKONTROL ATEX / NFPA ADDITIONAL
ANTI-EXPLOSIVE DATA

IMAGE OF A ATEX / NFPA."PETROL STATION MANHOLE REFUELING POINT WITHOUT

TECHNOKONTROL ANTI-EXPLOSION ALLOYS"-

34
IMAGE: ATEX/NFPA. SAFETY DIRECTIVES FOR ATMOSPHERIC GAS / PETROL-
CHEMICAL RISK-EXPLOSION ZONES

Guide to the ATEX directives

IMAGE:ATEX/NFPA- EXTREME DANGER-DISCHARGING OF EXPLOSIVE GASES/VAPOURS AT
PETROL STATIONS, MANHOLES, STORAGE TANKS

35
TECHNOKONTROL ATEX / NFPA ADDITIONAL
ANTI-EXPLOSIVE DATA

IMAGE: ATEX / NFPA - ANTI-EXPLOSION / SAFETY DISCHARGING - REFUELING VALVES FOR

PETROL STATIONS, FUEL DEPOTS, REFINERIES, PETROL- CHEMICAL PLANTS.

IMAGE: ATEX / NFPA- ANTI EXPLOSION, ANTI-ELECTROSTATIC, ANTI-SLOSHING, ANTI-

VAPOR SAFETY VALVES "CUSTOM MADE" FOR EACH CLIENT AND TECHNICAL-
INSTALLATION REQUIREMENTS.

36
ATEX-/NFPA PETROL STATIONS-MAN HOLES, STORAGE FACILITIES, REFUELING
AREAS- ATEX-EU/NFPA EXPLOSIVE ATMOSPHERIC DIRECTIVE DANGER SECTIONS

Guide to the ATEX directives

TK-SIAPS MANHOLES/ARQUETAS

FUEL TANKS SAFETY TECHNLOGIES

37
ATEX – TK SAFETY DIRECTIVES

ATEX-NFPA TECHNOKONTROL ANTI-EXPLOSION-SPECIALIST SAFETY TECHNOLOGIES

SPECIALIST UNIQUE PATENTED ALLOY FORMULATIONS & DESIGNS FOR ALL

ENGINEERING-TECHNICAL REQUIREMENTS INCLUDING USAGE FROM PROTECTION-
SAFETY TECHNOLOGIES TO PETROL-CHEMICAL-ENVIRONMENTAL INDUSTRIES:

38
TECHNOKONTROL SPECIALIS ANTI-VAPORIZATION, ANTI-THERMAL, & ANTI-
ELECTROSTATIC CHARGES ALLOYS FORMULATIONS.

Guide to the ATEX directives

ANTI-EMPS (ELECTROMAGNETIC PULSES/RADIATION), SPACE/SATELLITE/AVIATION
EXTREME THERMAL HEAT ATMOSPHERIC RE-ENTRY ALLOYS, ETC.

39
ATEX DIRECTIVE IN EU SAFETY DIRECTIVES, WHAT DOES THIS MEAN
FOR MY COMPANY PROTECTION & SAFETY NEEDS?

The ATEX directive consists of two EU directives describing what equipment and work
environment is allowed in an environment with an explosive atmosphere
Contents

Directives

The CE mark which should be attached to EU certified equipment

Mark for ATEX certified electrical equipment for explosive atmospheres.

As of July 2003, organizations in EU must follow the directives to protect employees from explosion
risk in areas with an explosive atmosphere.
There are two ATEX directives (one for the manufacturer and one for the user of the equipment):
 the ATEX 95 equipment directive 94/9/EC, Equipment and protective systems intended for use in
potentially explosive atmospheres;
 the ATEX 137 workplace directive 99/92/EC, Minimum requirements for improving the safety and
health protection of workers potentially at risk from explosive atmospheres.
Employers must classify areas where hazardous explosive atmospheres may occur into zones. The
classification given to a particular zone, and its size and location, depends on the likelihood of an
explosive atmosphere occurring and its persistence if it does.

40
Areas classified into zones (0, 1, 2 for gas-vapor-mist and 20, 21, 22 for dust) must be protected

Guide to the ATEX directives

from effective sources of ignition. Equipment and protective systems intended to be used in
zoned areas must meet the requirements of the directive. Zone 0 and 20 require Category 1
marked equipment, zone 1 and 21 require Category 2 marked equipment and zone 2 and 22
require Category 3 marked equipment. Zone 0 and 20 are the zones with the highest risk of an
explosive atmosphere being present.

Equipment in use before July 2003 is allowed to be used indefinitely provided a risk
assessment shows it is safe to do so.

The aim of directive 94/9/EC is to allow the free trade of ‘ATEX’ equipment and protective
systems within the EU by removing the need for separate testing and documentation for each
member state.

The regulations apply to all equipment intended for use in explosive atmospheres,
whether electrical or mechanical, including protective systems. There are two categories of
equipment 'I' for mining and 'II' for surface industries. Manufacturers who apply its provisions
and affix the CE marking and the Ex marking are able to sell their equipment anywhere within
the European union without any further requirements with respect to the risks covered being
applied. The directive covers a large range of equipment, potentially including equipment used
on fixed offshore platforms, in petrochemical plants, mines, flour mills and other areas where a
potentially explosive atmosphere may be present.

In very broad terms, there are three preconditions for the directive to apply: the equipment a)
must have its own effective source of ignition; b) be intended for use in a potentially explosive
atmosphere (air mixtures); and c) be under normal atmospheric conditions.

The directive also covers components essential for the safe use and safety devices directly
contributing to the safe use of the equipment in scope. These latter devices may be outside the
potentially explosive environment.

41
Manufacturers/suppliers (or importers, if the manufacturers are outside the EU) must ensure that their
products meet essential health and safety requirements and undergo appropriate conformity
procedures. This usually involves testing and certification by a ‘third-party’ certification body (known
as a Notified Body e.g. Sira, Intertek, Baseefa, Lloyd's, BAM,TUV) but manufacturers/suppliers can
‘self-certify’ Category 3 equipment (technical dossier including drawings, hazard analysis and users
manual in the local language) and Category 2 non-electrical equipment but for Category 2 the
technical dossier must be lodged with a notified body. Once certified, the equipment is marked by the
‘CE’ (meaning it complies with ATEX and all other relevant directives) and ‘Ex’ symbol to identify it as
approved under the ATEX directive. The technical dossier must be kept for a period of 10 years.

Certification ensures that the equipment or protective system is fit for its
purpose and that adequate information is supplied with it to ensure that it can be used safely. There
are four ATEX classification to ensure that a specific piece of equipment or protective system is
appropriate and can be safely used in a particular application: 1. Industrial or Mining Application; 2.
Equipment Category; 3. Atmosphere; and 4. Temperature.

The ATEX as an EU directive finds its US equivalent under the HAZLOC standard. This standard given
by the Occupational Safety and Health Administration defines and classifies hazardous locations such
as explosive atmospheres.

Technical definitions
What is an explosive atmosphere?

In DSEAR, an explosive atmosphere is defined as a mixture of dangerous substances with air, under
atmospheric conditions, in the form of gases, vapours, mist or dust in which, after ignition has occurred,
combustion spreads to the entire unburned mixture.

Atmospheric conditions are commonly referred to as ambient temperatures and pressures. That is to
say temperatures of –20°C to 40°C and pressures of 0.8 to 1.1 bar.

42
Zone classification

Guide to the ATEX directives

North
European and IEC
Definition of zone or division American
Classification
Classification

Class I
Zone 0 (gases / An area in which an explosive mixture is continuously
Division 1
Vapors) present or present for long periods
(gases)

Class I
Zone 1 (gases / An area in which an explosive mixture is likely to occur in
Division 1
Vapors) normal operation
(gases)

An area in which an explosive mixture is not likely to occur Class I

Zone 2 (gases /
in normal operation and if it occurs it will exist only for a Division 2
Vapors)
short time. (gases)

Class II
An area in which an explosive mixture is continuously
Zone 20 (dusts) Division 1
present or present for long periods
(dusts)

Class II
An area in which an explosive mixture is likely to occur in
Zone 21 (dusts) Division 1
normal operation
(dusts)

An area in which an explosive mixture is not likely to occur Class II

Zone 22 (dusts) in normal operation and if it occurs it will exist only for a Division 2
short time. (dusts)

43
 Effective ignition source

Effective ignition source is a term defined in the European ATEX directive as an event which, in
combination with sufficient oxygen and fuel in gas, mist, vapor or dust form, can cause an
explosion. Methane, hydrogen or coal dust are examples of possible fuels.

Effective ignition sources are:

 Lightning strikes.

 Open flames. This varies from a lit cigarette to welding activity.

 Mechanically generated impact sparks. For example, a hammer blow on a rusty steel
surface compared to a hammer blow on a flint stone. The speed and impact angle
(between surface and hammer) are important; a 90 degree blow on a surface is relatively
harmless.

 Mechanically generated friction sparks. The combination of materials and speed

determine the effectiveness of the ignition source. For example 4.5 m/s steel-steel friction
with a force greater than 2 kN is an effective ignition source. The combination of
aluminium and rust is also notoriously dangerous. More than one red hot spark is often
necessary in order to have an effective ignition source.

 Electric sparks. For example a bad electrical connection or a faulty pressure transmitter.
The electric energy content of the spark determines the effectiveness of the ignition
source.

 High surface temperature. This can be the result of milling, grinding, rubbing, mechanical
friction in a stuffing box or bearing, or a hot liquid pumped into a vessel. For example the
tip of a lathe cutting tool can easily be 600 Celsius (1100 °F); a high pressure steam pipe
may be above the autoignition temperature of some fuel/air mixtures.

 Electrostatic discharge. Static electricity can be generated by air sliding over a wing, or a
non-conductive liquid flowing through a filter screen.

 Radiation.

 Adiabatic compression. Air is pumped into a vessel and the vessel surface heats up.

44