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FEATURE MACHINE BUILDING, FRAMEWORKS & SAFETY E


x-rated equipment has been classified as safe for use in hazardous areas as it is designed to contain or prevent any


sparks, flames or explosions. However, poor installation of EX equipment can compromise its integrity. Detailed inspections prior to first use will help to identify potential installation quality issues, as well as ensuring the equipment is suitable for use. In the European Union there are two ATEX


Directives – one for the manufacturer and one for the user of the equipment. The ATEX 114 ‘equipment’ Directive 2014/34/EU focuses on the responsibilities ofmanufacturers of Ex-rated machinery and other equipment. In the UK, it is implemented by The Equipment and Protective Systems Intended for Use in Potentially Explosive Atmospheres Regulations 2016, which is law.


CONFORMING WITH THE REQUIREMENTS The legislation’s function is to ensure that the design andmanufacture of equipment intended for explosive atmospheres conforms with the Essential Health and Safety Requirements, so that these are met before anything is placed on the market. This is typically achieved by third-party testing and certification by an Approved or Notified Body. However, aftermachinery has been installed, how can you verify that conformity and compliance have been achieved? To ensure the installation quality and integrity


of Ex-rated equipment post installation, an intrusive inspection by a competent person should be carried out. This is described within the requirements of EN60079-17 as an ‘Initial Detailed Inspection’. If carried out correctly, such an inspection will ensure that the equipment, including its internal and external components, are fit for purpose and installed correctly. Manufacturers spend thousands of pounds


designing and testing equipment intended for explosive areas, and typically the end-user will pay a premium for these products. So, if your installer compromises themanufacturer’s design, this invalidates the equipment and creates a potentially dangerous installation. Theymight, for example, discard cable gland internals and decide that the simplest way to hang an Ex-rated light fitting is to drill through the casing to mount it, or they might drill and tap the lid of an Ex-rated enclosure to fit an identification label. Furthermore, assuming the issue is identified,


there will be a significant financial cost to re- establish compliance. This is so often the case when an end-user takes delivery of, for example,


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PREVENTING EX COMPLIANCE ISSUES


Although EX-rated equipment is designed to be safe for use in hazardous areas, poor installation can compromise its integrity. Darren


Hugheston-Roberts, head of Machinery Safety at TÜV SÜD, explains why initial inspections in hazardous areas are so important


a packaged skid assembly which has been manufactured off-site at a supplier’s premises. In such circumstances, Ex-related issues are only found during the completions, inspections and commissioning process. The consequence will be delays to commissioning and potentially start-up, alongside unplanned additional financial costs. Installer competency is often a key issue.


Keeping a core team of trades people as permanent employees is not always financially viable so it is common for suppliers and installers to hire workers for ad-hoc projects. This makes the assurance of installer competency a difficult area to manage.


THE BIGGER PICTURE However, the problemcan bemore systemic, and looking at the bigger picture the questionsmight be: Did the supplier fully understand what they were asked to build and to what standard?Were the specifications and design documents supplied


“The ATEX 114 ‘equipment’ Directive 2014/34/EU focuses on the responsibilities


of manufacturers of


Ex-rated machinery and other equipment”


Darren Hugheston-Roberts 1 DESIGN SOLUTIONS OCTOBER 2022 2


by the end-user or designer adequate? Did they cover the required legislative areas correctly and suitably? Were the appropriate standards referenced? At this point in a project disputes and frustrations are common, which can lead to further delays and cost – all of which can be avoided. Employing competent, impartial and


independent Ex Inspectors to inspect installations and carry out detail inspections prior to initial use, or in the case of the suppliers, prior to shipping, is a key element to detecting and rectifying problems early. Engaging a competent inspector tomonitor the build, offer advice and potentially mentor as the installation progresses, is an area that is often overlooked. However, by doing so there is significant potential to minimise or eliminate the need of rework after inspection. Another area that is commonly discounted is


the use of an independent and impartial specialist to review the technical documentation and project deliverables with respect to the installation of Ex electrical and non-electrical equipment. Design reviews, alongside build monitoring and inspection during the whole lifecycle of the project, will ensure both compliance and quality are achieved first time and on time. Ensuring that the supplier or installer knows


exactly what they are tasked with delivering is key to ensuring the safe and successful delivery of new Ex installations. Specifying the scope and required level of competency is therefore vital, alongside the involvement of competent people in the design, procurement and installation in order to help tomitigate Ex compliance issues.


TÜV SÜD www.tuvsud.com/uk


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