ATEX: A Pragmatic Approach to the Maintenance of Machinery

Installed within Hazardous Areas

AUTHOR: Andrew M Hollins AMIMechE ABB Engineering Services

Date: 1 February 2008

SYNOPSIS

Under the ATEX 137 Directive (1999/92/EC) (1) Employers have an on-going duty to ensure
that equipment installed within areas classified as hazardous is safe for operation within the
zoned areas and that it is maintained so that the means of protection against potential sources
of ignition remains effective.

Electrical equipment installed in such areas is generally well covered by established practices
for inspection and maintenance supported by standards and nationally recognised training
schemes for technicians. The absence of equivalent standards for mechanical equipment has
resulted in many maintenance managers and engineers being unsure as to how to fulfil their
duties in this regard.

This paper proposes an approach to the inspection and maintenance of mechanical equipment
installed in the zoned areas. The approach is based upon risk assessment and the application
of established maintenance techniques. The paper considers these with regard to the
maintenance of rotating equipment.

The author trusts that maintenance managers and engineers will be able to draw upon this
approach in developing appropriate maintenance plans for the machinery installed in
hazardous areas at their own sites. The author further hopes that this paper will be of use to
the wider mechanical engineering community in drafting relevant practical guidance
documents and standards.

It should be noted that this paper provides a summary of the authors considered opinion and
is not intended for use as the sole basis for determining compliance with the law within EU
member states.

INTRODUCTION

There are two ATEX Directives. The name comes from the French words ATmosphres
EXplosibles.

ATEX 137 aims to protect employees from the hazards associated with flammable substances
in the workplace. This Directive requires the Employer to undertake risk assessments of
workplaces in which flammable substances are used and to implement measures to eliminate
and control the risks to employees. This Directive came into full effect for new and modified

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workplaces from 30 June 2003. There was a three year transitional period for Employers to
achieve compliance for existing workplaces.

The other ATEX Directive, ATEX 95 (1994/9/EC) (2), covers the supply of equipment for
installation in potentially flammable atmospheres. This Directive requires the suppliers of
such equipment to meet specific safety criteria. The equipment must be designed and
constructed in line with Essential Safety Requirements (ESRs). It must also be appropriately
tested and certified and marked in a prescribed manner. Additionally the supplier has a duty
to maintain the necessary technical records.

The two ATEX Directives are complimentary and together have the effect of turning what
had previously been accepted best practice within the process industries into mandatory
requirements. Under ATEX the definition of equipment for use within hazardous areas was
extended to include mechanical equipment. Prior to the implementation of ATEX only
electrical equipment for installation in such areas had been given special consideration.

The need to consider mechanical equipment as a potential source of ignition and to inspect
and maintain it in such a way so as to prevent these sources of ignition becoming effective is
one of the main challenges for maintenance managers and responsible engineers.

Until the introduction of the ATEX Directives there was relatively little consideration given
to the potential ignition sources associated with mechanical equipment. Hazard and
operability (HAZOP) studies may have identified potential issues with flames and very hot
pipework. The authors experience is that ignition sources from fluid machinery were usually
discounted, apart from the possible specification of non-sparking guards and couplings.

HAZARDOUS AREA CLASSIFICATION

Under ATEX area classification has become a requirement for all workplaces handling
significant quantities of flammable substances. The methodology for area classification is set
out in EN 60079-10 (3). In undertaking the area classification all locations where explosive
atmospheres are likely to be present are classified as either hazardous or non-hazardous areas.
The hazardous areas are then divided into zones according to the likely frequency and
duration of the presence of the explosive atmosphere. The installation of equipment within
the zoned areas is restricted. The definition of the hazardous zones and the restrictions as to
type of equipment that can be used within them are detailed in the Annexes to 1999/92/EC.

With effect from 1 July 2003 only ATEX compliant equipment can be installed within a
zoned area. New mechanical equipment for installation in potentially flammable atmospheres
is covered by the EN 13463 series of standards. EN 13463-1 (4) covers the basic method and
requirements for such equipment. The other standards in this series cover the various types of
protection the equipment manufacturer can employ to prevent potential ignition sources
becoming effective.

The restrictions on the type of equipment that can be installed within a given zone not only
has implications for the initial cost of the equipment but also for the operating and
maintenance costs throughout its operational life. The cost multiples vary according to the
type of equipment and can be significant. For example, the purchase cost of a category 1 fan
can be as much as 7 times the cost of the equivalent safe-area fan. Consequently the

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classification should be done thoroughly and carefully so as to avoid over or under zoning the
work area.

Special provisions apply to the continuing use of mechanical equipment that was in use
before 30 June 2003. These are discussed in the following sections.

MECHANICAL EQUIPMENT INSTALLED IN HAZARDOUS AREAS

Mechanical equipment has the potential to introduce ignition sources into the hazardous
areas. EN 1127-1 (5) lists some 13 groups of ignition source. Of these the most common ones
associated with fluid machinery are hot surfaces, flames, hot gases, mechanically generated
sparks and static electricity. Some of the potential ignition sources associated with a typical
centrifugal pump are shown in figure 1.

Bearing temperature / failure

Guard
catching
shaft
Static
discharge

Surface
temperature

Coupling rub

Hot seal / throttle bush

Figure 1: Potential Ignition Sources Centrifugal Pump

New equipment (i.e. equipment purchased after 1 July 2003) for installation within the zoned
areas must carry both CE and EX marks as well as other marking as required by the ATEX
equipment supply Directive, 94/9/EC. It must also be accompanied by a declaration of
conformity. This document and the installation operating and maintenance manuals must
refer to any necessary conditions or requirements. Together these documents are the means
by which the supplier tells the equipment user how to install, operate and maintain the
equipment so that it safe for its intended purpose.

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It should be noted that the declarations of conformity for fluid machinery are generally
conditional upon the following:

Correct installation of the equipment

Operation within specified limits
Specific operating and maintenances procedures (usually detailed within the
Operations & Maintenance manual)

For some types of mechanical equipment one or more of the following may also be required:

Specific time-based maintenance activities

Condition monitoring regimes
The installation of protective trips / alarms and / or hardware protection
devices

The key point to appreciate is that the declaration of conformity and the associated
installation, operation and maintenance instructions are the means by which the equipment
supplier communicates to the user of the equipment the requirements for the safe installation,
operation, inspection and maintenance of the equipment. Consequently the suppliers
documentation must clearly state all the measures necessary for the equipment to be safe
when used as intended. In the case of equipment intended for installation within the zoned
areas this must include the measures necessary to prevent potential ignition sources becoming
effective.

With regard to mechanical equipment in use prior to 30 June 2003 it was not intended that the
introduction of the ATEX Directives would lead to its wholesale replacement with new,
ATEX compliant, equipment. Provided that the Employer can show that the equipment is
safe for use within the hazardous area it can continue to be used indefinitely. Consequently
one effect of the implementation of ATEX is to permit the use of fluid machinery beyond 30
June 2003 providing that risk assessment shows that it is safe to do so.

Fluid machinery installed prior to 30 June 2003 will not have been designed and built to
standards which directly addressed the potential for the equipment to become an ignition
source. The machinery installed in typical process plants will have been built to the
prevailing industry standards for that type of equipment.

Risk assessments for fluid machinery normally identify a range of potentially effective
ignition sources. In many cases the ignition sources can be eliminated / controlled / mitigated
by the application of one or combinations of the measures shown below:

Maintenance and operational procedures.

Process operator checks.
Maintenance inspections and records.
Condition monitoring regimes.
Instrumented trips and alarms
Hardware protection devices.

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It follows that the inspection and maintenance of the equipment installed within the
hazardous areas must focus upon preventing the potential ignition sources becoming
effective.

INSPECTION & MAINTENANCE OF ELECTRICAL EQUIPMENT

Electrical engineers have been considering electrical apparatus installed within the zoned
areas for over 30 years. During this period best practice has become established and
supporting standards have been produced and revised. The relevant standards for electrical
apparatus are the EN 60079 series. These standards are aimed at preserving the integrity of
the installation.

EN 60079-17 (5) is the standard covering the inspection of electrical apparatus. This standard
establishes a framework of systematic regular inspections and details what needs to be
inspected and when the inspections should be carried out. The standard defines three types of
inspection (pre-commissioning, periodic and sample) and three grades of inspection (visual,
close and detailed). The scheme of inspection is to be planned and managed and a responsible
person has to be nominated. The inspections are to be undertaken by trained technicians.

In order to effectively manage the scheme detailed inspection records are required and it is
necessary to keep the area classification documentation up to date.

EN 60079-19 (6) is the standard covering the repair of electrical equipment. This standard
details the responsibilities of the repairer, the equipment manufacturer and the user. The
standard requires that electrical apparatus must be marked to show that it has been repaired.

So that technicians working electrical apparatus installed in the zoned areas are appropriately
trained recognised competency schemes have been established. Within the UK CompEX is
an example of such a scheme.

INSPECTION & MAINTENANCE OF MECHANICAL EQUIPMENT

As we have seen in the previous section electrical equipment is covered by a comprehensive

set of standards supporting established best practise. The key question for mechanical
engineers is what to do in the absence of equivalent standards covering mechanical
equipment.

The answer to this may be somewhat surprising because it is so obvious. Indeed, maintenance
managers and responsible mechanical engineers should already have the essential elements to
comply with the maintenance requirements of ATEX in place. However they may not have
appreciated this and / or may need to formalise what they already do.

All of the information necessary for the inspection and maintenance of the mechanical
equipment is or should be available to the engineer. Figure 2 provides a summary of where
the necessary information comes from. As was discussed in an earlier section, mechanical
equipment installed in the zoned areas should be ATEX compliant, if purchased after 30 June
2003. For this equipment the inspection and maintenance requirements are defined within the
documentation supplied with the equipment. The supplier is required to do this under the

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equipment supply Directive. For equipment in use on or before 30 June 2003 the Employer
should have undertaken an ignition source risk assessment. This assessment will have
identified the inspection and maintenance measures necessary for the equipment to continue
to be operated safely within the zoned area.

Inspection &
Maintenance
Requirements

New Existing
Equipment Equipment

Manufacturers
Declaration of Conformity
Mechanical Equipment
& Risk Assessments
Installation, Operation &
Maintenance Manual

Figure 2: Sources of Information for Defining the Inspection & Maintenance

Requirements for Mechanical Equipment Installed in Hazardous Areas

It is not appropriate to try to apply the inspection schemes within EN 60079-17 for electrical
apparatus to mechanical equipment since fluid machinery generally requires much more
frequent inspection. For example a look / listen / feel inspection of fluid machinery is
broadly similar to a close inspection of electrical apparatus. However, the inspection would
normally be undertaken each shift as opposed to 3 yearly for the electrical inspection. The
results of look / listen / feel inspections are normally not recorded.

For fluid machinery the inspection regime is established within the operator and maintenance
technician checks and the preventative maintenance and condition monitoring routines. It is
therefore important that these checks and routines are carried out and that appropriate records
are maintained. The inspection regime and the records of the inspections need to be auditable.

The author is aware of a number of process plants where the rotating equipment has been bar
coded and the technicians have been issued with hand-held data loggers to record the look /
listen / feel inspection and other inspections. This data together with the records of the
preventative maintenance routines undertaken within the maintenance management system
and the results of the condition monitoring inspections provide a comprehensive set of
records for the equipment.

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EXAMPLE 1: INSPECTION & MAINTENANCE OF A CENTRIFUGAL PUMP

This can be illustrated by considering a centrifugal pump installed within a hazardous area in
a refinery. The pump is handling a flammable fluid and is installed within a zone 1 area. This
pump was installed and operating prior to 30 June 2003.

So as to permit this pump to continue to operate within the zoned area an ignition source risk
assessment was undertaken. The factors considered in this assessment are shown in figure 3.

C en trifu g al P u m p

Ra dial / M echa nical C oupling S ha ft Im peller P rocess E le ctro statics

Thrust S eal Fa ilu re F ailure F ailure Fa ilu re C ondition
B earing
F ailu re

A pplies to horizo ntal ba ck pu ll out centrifuga l pum p, with m ech anical seal.

Figure 3: Fault Tree for a Centrifugal Pump

The ignition source assessment concluded that the pump can continue to be operated safely
within the zoned area providing that the control and elimination measures identified by the
assessment are in place. For this pump these measures included the following.

Regular (daily or each shift) tours by the plant operators during which the pump is
subject to a look / listen / feel inspection.

Preventative maintenance routines covering scheduled lubrication and other

inspections and checks by the maintenance technicians.

A periodic condition monitoring regime covering vibration / temperature / oil

sampling.

Systems in place to control the quality of the overhaul of the pump including manuals,
machinery build quality plans, use of the correct spares, and trained maintenance
technicians.

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Had this pump been purchased after 30 June 2003 the inspection and maintenance measures
identified by the equipment supplier in the Declaration of Conformity and the installation,
operations and maintenance manuals are likely to be broadly similar in nature.

This pump had previously been identified as production / safety critical and the maintenance
manager had already put most of these measures in place to ensure that the pump continues to
operate with the required reliability. It was found that in respect of a number of areas the
inspection and maintenance regime already in place for this pump was more comprehensive
than the minimum requirements identified within the ignition source assessment.

The action upon the maintenance manager is to demonstrate that the measures identified
within the risk assessments or required by the declarations of conformity are in place and are
effective. This has been achieved by regular auditing of the operating and maintenance
systems.

REPAIRS & MODIFICATIONS TO MACHINERY

Anything other than the like-for-like replacement of a component or assembly should be

treated as a repair or potential modification to the equipment.

In the case of equipment purchased since 1 July 2003 any repair or modification could
invalidate the suppliers certification for the equipment. For equipment in use on or before 30
June 2003 a repair or modification could affect the safety case established by the risk
assessment. In either eventuality the Employer is taking on the responsibility for the safety of
the equipment in its repaired or modified condition.

Consequently repairs or modifications to fluid machinery installed within hazardous areas

should be controlled by a management of change procedure and should be recorded. The
maintenance manager or responsible engineer the needs to give detailed consideration to the
following:

The change alters the nature of the hazard(s) associated with the equipment.

The change increases the risk from an existing hazard.

The change potentially alters the function of the equipment in a manner which could
not reasonably have been foreseen by the manufacturer.

This is explored in greater detail in the examples given below but in each case it must be
remembered that the responsibility for the safety of the repaired or modified equipment
remains with the Employer regardless of where or by whom the work is undertaken.

The management of change procedure needs to control what happens within the Employers
own workshops and equipment sent out for repair or modification by a third party (i.e. a
specialist machinery overhaul company).

EN 60079-19, the repair standard for electrical apparatus, is not directly applicable to
mechanical equipment. Much of this standard is concerned with achieving the necessary
containment or the correct gap to prevent internal electrical sparks igniting an atmosphere

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external to the equipment. However, the part of the standard concerning the repair of electric
motor shafts may be useful as providing some basis for controlling the repair of damaged
shafts in fluid machinery.

EXAMPLE 2: REPLACEMENT OF BEARINGS

In the case of rolling element bearings like-for-like replacement with a bearing of the same
specification is usually a straightforward matter that does not involve a modification to the
equipment. However, care needs to be exercised as bearings having the same bearing number
but from different manufacturers can differ significantly in ways that might affect the safety
of the equipment. For example, tapered roller bearings from different manufacturers can have
different taper angles.

Plain and white metal bearings can be more problematic, particularly for machinery where
the original equipment manufacturer either no longer exists or is no longer able or willing to
supply spares for the equipment. In this case the new bearings must be treated as a potential
modification and the replacement bearings need to be covered by a management of change
procedure. To permit the equipment to continue in service with the existing safety assessment
detailed consideration will need to be given to the criteria discussed on the previous page.
The maintenance manager or responsible engineer will need to be able to demonstrate that the
new bearings have been designed for the loads and manufactured to achieve the required
quality.

EXAMPLE 3: SHAFT REPAIR / REPLACEMENT

If a replacement shaft is not available from the original equipment manufacturer there will be
little option but to repair the damaged shaft or replace it if the machinery is to remain in
service. Both of these circumstances should be treated as a potential modification and
controlled by the management of change process. The safety implications of fitting the
repaired or replacement shaft needs to be given careful consideration.

The shaft repair will need to be fully specified. The advice of a metallurgist and / or a
welding engineer may be required in order to specify the repair. The following will need to
be specified: inspection and preparation of the shaft prior to repair, welding consumables,
weld technique, weld quality, stress relieving, NDT, machining to correct surface finish and
dimensions.

Particularly for old machinery there may be no option but to manufacture a new shaft. The
new shaft must be fully engineered for the machine with the material specified and fully
dimensioned drawings with particular attention to surface finishes and radii at undercuts.
Manufacturing must be done with an appropriate level of quality control.

EXAMPLE 4: REPLACEMENT OF AN IMPELLER

Taking an impeller supplied by the original equipment manufacturer for a pump and
trimming the impeller to give the required hydraulic performance might not be regarded as a
modification unless the diameter of the impeller is outside the design range for the pump and

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the process system. If this is the case the management of change procedure should be
initiated.

Should the original equipment supplier be unable to supply a replacement impeller, the
manufacture of a new impeller should be treated in the same manner as the production of a
new shaft.

COMPETANCY FOR MECHANICAL TECHNICIANS

The existing competency schemes for electrical technicians have no relevance to the work
performed by mechanical technicians since they are aimed at preserving the integrity of the
electrical apparatus. How then can the maintenance manager or responsible engineer ensure
that their technicians are competent to work on the fluid machinery installed within the zoned
areas? Until such time as recognised competency training schemes for mechanical
technicians are available the following is suggested.

The technicians should already have the basic competence necessary to perform their normal
tasks maintaining and overhauling fluid machinery. This should be supplemented by:

Basic ATEX and hazardous awareness training.

Instruction & information as to the measures in place on the site

Details as to the specific measures identified as necessary for the equipment by the
risk assessments or the equipment suppliers documentation.

The technicians basic mechanical competence needs to be supplemented by sufficient

knowledge to ensure that the integrity of the fluid machinery is preserved and active ignition
sources are prevented.

CONCLUSION

Although there are currently no standards covering the inspection and maintenance of fluid
machinery installed within hazardous areas, all of the elements necessary to establish
inspection and maintenance regimes proportionate to the risk introduced by the equipment
are, or should be, available to maintenance managers and responsible engineers. In many
cases it has been found that current best practise is sufficient to manage the risk.

The safety implications of repairs and modifications need to be carefully assessed. They need
to be fully engineered and subject to control by a rigorous management of change procedure.

The concepts explored in this paper may additionally be of use to the mechanical engineering
community as the starting point for drafting relevant practical guidance documents and
engineering standards.

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REFERENCES
1 ATEX 137 European Union Directive 1999/92/EC.

2 ATEX 95 European Union Directive 1994/9/EC.

3 EN 60079-10 Electrical apparatus for explosive gas atmospheres.

Part 10: Classification of hazardous areas.

4 EN 13463-1 Non-electrical equipment for potentially explosive atmospheres.

Part 1: Basic method & requirements.

5 EN 1127-1 Explosive atmospheres. Explosion prevention and protection.

Part 1: Basic concepts and methodology.

6 EN 60079-17 Explosive atmospheres.

Part 17: Electrical installations inspection and maintenance.

7 EN 60079-19 Explosive atmospheres.

Part 19: Equipment repair, overhaul and reclamation.

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