Understanding the ATEX Directive 2014/34/EU: Key Requirements and Applications

ATEX Directive 2014/34/EU serves as a critical regulatory framework ensuring safety in potentially explosive atmospheres. It is not only a legislative tool but also a guide for engineers to ensure their designs and products meet the highest safety standards. This article delves into the directive’s requirements and practical applications across various industries.

What is the ATEX Directive?

The ATEX Directive 2014/34/EU (Atmosphères Explosibles) encompasses European Union regulations governing equipment and protective systems intended for use in potentially explosive atmospheres. Its primary goal is to safeguard people and property by minimizing explosion risks in industrial settings.

History and Evolution of the ATEX Directive

The ATEX Directive originated from earlier workplace safety regulations. Initial regulations emerged in the 1990s, with the current version, 2014/34/EU, adopted in 2014. It replaced the previous directive 94/9/EC, introducing more detailed requirements for product marking and certification.

ATEX Directive: Conformity Assessment Procedure

The ATEX Directive 2014/34/EU establishes various conformity assessment procedures for equipment and protective systems intended for use in potentially explosive atmospheres. The following outlines when specific modules and conformity assessment groups apply:

Module Descriptions:

• Module A: Internal production control.
• Module B: EU-type examination.
• Module C1: Conformity to type based on internal production control plus supervised product checks.
• Module D: Conformity to type based on quality assurance of the production process.
• Module E: Conformity to type based on product quality assurance.
• Module F: Conformity to type based on product verification.
• Module G: Conformity based on unit verification.

Understanding ATEX Categories:

• Group I: Equipment for use in underground mines and parts of surface installations of such mines, endangered by firedamp and/or combustible dust.
  • Category M1: Equipment providing a very high level of safety, remaining operational and safe even in explosive atmospheres.
  • Category M2: Equipment providing a high level of safety, intended to be de-energized in explosive atmospheres.
• Group II: Equipment for use in other places endangered by explosive atmospheres.
  • Category 1: Equipment for use in areas where explosive atmospheres are present continuously, for long periods, or frequently, ensuring a very high level of safety.
  • Category 2: Equipment for use in areas where explosive atmospheres are likely to occur occasionally, ensuring a high level of safety.
  • Category 3: Equipment for use in areas where explosive atmospheres are unlikely to occur or occur infrequently and for short periods, ensuring a normal level of safety.
• Group III: Equipment for use in places where explosive atmospheres consist of combustible dust.
  • Category 3: Equipment for use in areas where explosive atmospheres occur infrequently and for short periods, ensuring a normal level of safety.

This categorization of equipment and conformity assessment modules assists in tailoring appropriate procedures based on the risk level associated with using the equipment in potentially explosive atmospheres.

Module A: Internal Production Control

1. Technical Documentation:
   • The manufacturer compiles technical documentation enabling the assessment of the product’s conformity with the directive’s requirements. This documentation includes a general product description, technical drawings, schematics, descriptions, and test results.
2. Production:
   • The manufacturer ensures product conformity with the technical documentation and directive requirements through appropriate control measures during production.
3. CE Marking:
   • The manufacturer affixes the CE marking to the product and drafts a written EU declaration of conformity, which is retained for 10 years after the product is placed on the market.

Module B: EU-Type Examination

1. Application:
   • The manufacturer submits an application for EU-type examination to a notified body, along with the technical documentation.
2. Examination:
   • The notified body reviews the documentation and conducts appropriate tests to confirm the type’s conformity with the directive’s requirements.
3. EU-Type Examination Certificate:
   • Upon successful verification, the notified body issues an EU-type examination certificate, identifying the type’s conformity with the directive’s requirements.

Module C: Conformity to Type Based on Internal Production Control

1. Production Control:
   • The manufacturer ensures that produced products conform to the type described in the EU-type examination certificate through appropriate control measures.
2. CE Marking:
   • The CE marking is affixed to the product along with the identification number of the notified body.
3. EU Declaration of Conformity:
   • The manufacturer drafts an EU declaration of conformity and retains it for 10 years after the product is placed on the market.

Module D: Conformity to Type Based on Quality Assurance of the Production Process

1. Quality System:
   • The manufacturer implements an approved quality system covering production, final product inspection, and testing.
2. Audit:
   • The notified body conducts audits of the quality system and may perform unannounced visits to verify its operation.

Module E: Conformity to Type Based on Product Quality Assurance

1. Quality System:
   • The manufacturer applies for an assessment of the quality system for specific products, ensuring conformity with the type described in the EU-type examination certificate.
2. Supervision:
   • The notified body conducts periodic audits and unannounced visits to verify product conformity.

Module F: Conformity to Type Based on Product Verification

1. Production and Verification:
   • The manufacturer ensures product conformity with the approved type and conducts verification tests.

Module G: Conformity Based on Unit Verification

1. Verification:
   • The notified body conducts appropriate tests on each product to confirm its conformity with the directive’s requirements.

These modules form a comprehensive conformity assessment system for products intended for use in potentially explosive atmospheres, ensuring their safety and compliance with European Union regulations.

Equipment Group I and II, Category M1 and 1:

1. Module B (EU-Type Examination) combined with one of the following:
   • Module D (Conformity to type based on quality assurance of the production process).
   • Module F (Conformity to type based on product verification).

Equipment Group I and II, Category M2 and 2:

1. Module B (EU-Type Examination) combined with one of the following:
   • Module C1 (Conformity to type based on internal production control plus supervised product checks).
   • Module E (Conformity to type based on product quality assurance).
2. For other equipment in this group and category:
   • Module A (Internal production control) and submission of technical documentation to the notified body, which confirms its receipt and storage.

Equipment Group II, Category 3:

1. Module A (Internal production control).

Protective Systems:

1. Procedure compliant with Modules B and D or B and F.

Alternative Procedures:

1. Module G (Conformity based on unit verification) may be applied for equipment groups I and II.

Explosion Hazard Zones According to PN-EN IEC 60079

• Zone 0: Areas where explosive atmospheres are present continuously or for long periods.
• Zone 1: Areas where explosive atmospheres may occur during normal operation.
• Zone 2: Areas where explosive atmospheres do not occur during normal operation, and if they do, it is only for a short time.

Equipment Categories in the ATEX Directive

The ATEX Directive classifies equipment based on the level of protection they must provide in respective zones:

• Category 1: Equipment for use in places where explosive atmospheres are present continuously, frequently, or for long periods.
• Category 2: Equipment that can be used in places where explosive atmospheres occur occasionally.
• Category 3: Equipment for use in places where explosive atmospheres are unlikely to occur, and if they do, it is only for a short time.

Thus, based on explosion hazard zones, equipment categories should be applied as follows:

• Category 1: Equipment for zones 0, 1, and 2.
• Category 2: Equipment for zones 1 and 2.
• Category 3: Equipment for zone 2.

ATEX Directive: Risk Analysis and Design

The first step involves risk analysis, which identifies potential hazards associated with using equipment in explosive atmospheres. Key elements of this stage include:

• Strength calculations (FEM): Utilizing numerical methods to simulate and analyze structural strength. In explosive atmospheres, it is crucial to determine what explosive pressure may occur and how the equipment’s design withstands these forces.
• Machine design: Selecting appropriate components that can operate in explosive atmospheres. Sometimes, entire control systems must be pneumatic to avoid sparking and other ignition sources.

Selecting Appropriate Components

Machine design in compliance with the directive requires:

• Choosing appropriate components: Components must comply with ATEX Directive standards and be properly marked.
• Implementing safety technologies: In many cases, advanced technologies such as shielding systems, flameproof devices, or enhanced construction technologies are necessary to ensure compliance with the directive.

Production and Quality Control

Production must be closely monitored to ensure all equipment complies with designs and meets the directive’s requirements. Key activities include:

• Testing and validation: Conducting tests to ensure equipment operates correctly in explosive atmospheres.
• Safety audits: Regular audits and reviews to ensure compliance with standards.

ATEX Directive: CE and Ex Marking: When and How to Apply

CE Marking:

CE marking (Conformité Européenne) is required for all products placed on the market in the European Economic Area (EEA). It indicates that the product meets EU directives’ safety, health, and environmental protection requirements.

Ex Marking:

Ex marking is applied to equipment and protective systems intended for use in potentially explosive atmospheres. This marking indicates that the product has been designed and manufactured in accordance with the requirements of Directive 2014/34/EU (ATEX).

When to Apply Ex Marking Alongside CE:

Ex marking is placed alongside CE marking in the following cases:

1. Products intended for use in potentially explosive atmospheres:
   • All equipment and protective systems used in such atmospheres must have Ex marking to indicate compliance with Directive 2014/34/EU (ATEX).
2. Conformity assessment procedure:
   • Products that have undergone the appropriate conformity assessment procedure (e.g., Module B + Module D, Module B + Module F) are entitled to Ex marking. These procedures confirm that the product meets specific safety requirements related to explosion protection.
3. Technical documentation and EU declaration of conformity:
   • The manufacturer must have technical documentation and an EU declaration of conformity indicating product compliance with the ATEX directive. Ex marking is then placed on the product alongside CE marking.
4. Special explosion protection symbol:
   • Alongside CE and Ex markings, special explosion protection symbols are also placed, specifying the equipment group and category, as well as other information required by the ATEX directive.

Examples of Marking with Extensions According to IEC 60079:

• Example 1: Category 1 Equipment (Group II):
  • CE 0123 Ex II 1 G Ex d IIC T4 Gb
    • CE: Compliance marking with EU directives.
    • 0123: Identification number of the notified body (if applicable).
    • Ex: Compliance marking with the ATEX directive.
    • II: Equipment group (other than mines).
    • 1: Equipment category (very high level of protection).
    • G: Gas atmosphere application.
    • Ex d: Type of protection (e.g., flameproof enclosure).
    • IIC: Gas group (hydrogen, acetylene).
    • T4: Temperature class (maximum surface temperature 135°C).
    • Gb: Protection level (enhanced protection).
• Example 2: Category 2 Equipment (Group I):
  • CE 0123 Ex I M2 Ex ib I Mb
    • CE: Compliance marking with EU directives.
    • 0123: Identification number of the notified body (if applicable).
    • Ex: Compliance marking with the ATEX directive.
    • I: Equipment group (mines).
    • M2: Equipment category (high level of protection).
    • Ex ib: Type of protection (e.g., intrinsic safety).
    • I: Gas group (methane).
    • Mb: Protection level (enhanced protection).

Possible Extensions According to IEC 60079:

1. Types of Protection:
   • Ex d: Flameproof enclosure.
   • Ex e: Increased safety.
   • Ex n: Non-sparking.
   • Ex p: Pressurized enclosure.
   • Ex ia/ib/ic: Intrinsic safety.
2. Gas Groups:
   • I: Methane (mines).
   • IIA: Propane.
   • IIB: Ethylene.
   • IIC: Hydrogen, acetylene.
3. Temperature Classes:
   • T1: 450°C.
   • T2: 300°C.
   • T3: 200°C.
   • T4: 135°C.
   • T5: 100°C.
   • T6: 85°C.
4. Protection Levels:
   • Ga: Highest level of protection (Application in zone 0).
   • Gb: High level of protection (Application in zone 1).
   • Gc: Basic level of protection (Application in zone 2).

Using CE and Ex markings with appropriate extensions according to IEC 60079 ensures clarity and compliance of products with safety requirements in potentially explosive atmospheres.

ATEX Directive: Key Requirements

The directive imposes several requirements that equipment and protective systems must meet:

• Safety of Design: Equipment must be designed to minimize explosion risk even if one protective measure fails.
• Materials: Materials used must resist chemical reactions with explosive atmospheres.
• CE Marking: Every device must bear the CE mark, indicating compliance with the directive’s requirements.

Safety audits and harmonized standards play a crucial role in the certification process and ensuring compliance with the directive’s requirements.

ATEX Directive: Application in Various Industries

The ATEX Directive finds extensive application across various industrial sectors:

• Petrochemical Industry: Application in refineries, drilling platforms.
• Mining: Equipment used in mines must meet strict safety standards.
• Grain Mills: Requirements for process automation and safety.

In each of these industries, the role of industrial automation integrators and PLC programming specialists is crucial to ensuring compliance with the directive’s requirements.

ATEX Directive: Harmonized Standards

Within the ATEX Directive, numerous harmonized standards ensure consistency and safety in industrial automation. Standards from the PN-EN 60079-x series are particularly significant in the context of explosion protection. Here is an overview of the most important standards from this series:

1. PN-EN 60079-0: Explosive atmospheres – Part 0: Equipment – General requirements
   • Specifies general requirements for the design and testing of equipment intended for use in explosive atmospheres.
2. PN-EN 60079-1: Explosive atmospheres – Part 1: Equipment protection by flameproof enclosures “d”
   • Concerns equipment that prevents flame transmission to explosive atmospheres.
3. PN-EN 60079-2: Explosive atmospheres – Part 2: Equipment protection by pressurized enclosures “p”
   • Specifies principles for protecting equipment by applying gas overpressure inside the enclosure to prevent explosive atmosphere ingress.

Example Harmonized Standards Other than PN-EN 60079-x

Besides the PN-EN 60079-x series, other significant harmonized standards related to the ATEX Directive exist:

1. PN-EN 1834-1:2002: Reciprocating internal combustion engines – Safety requirements for design and construction of engines for use in potentially explosive atmospheres – Part 1: Group II engines for use in flammable gas and vapor atmospheres
   • Standards concerning the safety of design and construction of engines used in explosive atmospheres.
2. PN-EN 13463-1:2009: Non-electrical equipment for explosive atmospheres – Part 1: Basic methods and requirements
   • Specifies basic requirements and protection methods for non-electrical equipment intended for use in explosive atmospheres.
3. PN-EN 13760:2022-04: Equipment and accessories for LPG – LPG supply installations for light and heavy vehicles – Nozzles, test requirements, and dimensions
   • Concerns the safety of design and operation of LPG supply equipment used in explosive atmospheres.

The ATEX Directive is a key element in ensuring safety in potentially explosive atmospheres. Through proper practices, certification, and the implementation of advanced technologies, companies can effectively minimize explosion risks and ensure safe working conditions. In the context of industrial automation, the directive’s significance is particularly crucial, allowing for safe and efficient management of production processes. Harmonized standards, such as PN-EN 60079-x, play a vital role in achieving these goals.

FAQ: ATEX Directive

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