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Supporting an Equipment Manufacturer with an ATEX Feasibility Study for a Process Gas Analyser

The Challenge

An engineering contractor engaged EPIT to provide specialist explosion protection consultancy for a client seeking to deploy a multigas analyser within a Zone 2 hazardous area. While the analyser had been designed for use in non-hazardous environments, the client wanted to determine whether the existing design could be adapted to achieve compliance with the ATEX Directive 2014/34/EU.

The project required an independent engineering assessment to evaluate the suitability of the existing design for hazardous area use and identify the most practical explosion protection concepts, taking into account the equipment’s operating characteristics, environmental constraints and intended application.

Our Solution

EPIT carried out a detailed engineering feasibility study, reviewing the analyser design alongside the available technical documentation and applicable explosion protection standards.

The consultancy evaluated potential protection concepts in accordance with:

IEC 60079-0 – General Requirements
IEC 60079-1 – Flameproof Enclosures (Ex d)
IEC 60079-2 – Pressurised Enclosures (Ex p)

The objective was to determine which protection methods could realistically be applied to enable installation of the analyser within a Zone 2 hazardous area.

As part of the assessment, EPIT reviewed the analyser’s electrical design, enclosure construction, gas sampling system and operating parameters, together with the process gases, environmental conditions and installation requirements. Particular consideration was given to the handling of flammable process gases, potential ignition sources, enclosure integrity and the implications of continuous gas sampling.

The study also examined the practical engineering considerations involved in converting laboratory equipment into equipment suitable for hazardous area installation, ensuring that any proposed solutions were both technically achievable and aligned with the relevant standards.

The Outcome

The completed feasibility study provided the client with a clear engineering assessment of the available explosion protection concepts, together with an evaluation of the technical challenges associated with each approach.

By carrying out the feasibility study before committing to product redesign or certification, the client was able to make informed engineering and commercial decisions based on an independent technical review. The report established a practical route towards ATEX compliance while identifying the key design considerations and certification requirements that would need to be addressed during future development.

The project reduced technical risk at an early stage and provided a structured roadmap for developing a process gas analyser suitable for installation within Zone 2 hazardous areas.

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Header Column #1
Industries	Principal to all Ex environments, with direct application in hazardous vapour and gas environments.
Entry Qualifications Guidance	Level 3, ECS Gold Card, National Diploma or equivalent. Disipline: Electrotechnical Instrumentation Subject to knowledge, skill and experience candidates may benefit from Ex F+
Entry Knowledge - Expected	Knows the relevant legislative, regulatory, local requirements Understands procedures for safe working practice and systems of work in an industrial setting Can read and interpret relevant engineering drawings, related specifications, quality standards and equipment manuals Understands the hierarchy of responsibilities in relation to reporting and decision-making
Entry Skills - Expected	Practical skills in engineering assembly of a complexity consistent with that of a level 3 craftsperson Can apply safe working practices including safe isolation to meet the requirements of statutory and non-statutory regulations Can safely install, inspect, test, commission, diagnose and correct faults in electrical plant, instrumentation, associated cabling, cabling supports and equipment Can select, gland & terminate industrial type cables to a suitable component and associated cable tray in line with details on the appropriate specification Can interpret manufacturers documentation for correct installation,maintenance and inspection
Job Roles Aspiring to or operating in	Installation or Maintenance Electrician Electrical or Instrument Technician Engineers
Entry Experience Guidance	2 + years' experience operating in a site / industrial environment Installing, inspecting, testing and/or maintaining equipment in an industrial setting
Entry Knowledge - Desirable	Understands the need for and methods of achieving safe working practice in gas and vapour Ex environments Has basic practical, theoretical and technological knowledge and understanding of gas and vapour Ex environments Has a basic understanding of the requirements, materials and equipment considerations, in relation to working in gas and vapour Ex environments
Entry Skills - Desirable	Can select and install a variety of Ex certified cables glands and terminate conductors into equipment Can understand the principles of electrical protection concepts including selection, installation and maintenance Understands intrinsically safe concept of protection and installation including the importance of documentation Can inspect new and existing equipment in accordance with appropriate inspection techniques relevant to the different grades of inspection

Header Column #1

Industries

Principal to all Ex environments, with direct application in hazardous vapour and gas environments.

Entry Qualifications
Guidance

Level 3, ECS Gold Card, National Diploma or equivalent. Disipline:

Electrotechnical
Instrumentation

Subject to knowledge, skill and experience candidates may benefit from Ex F+

Entry Knowledge - Expected

Knows the relevant legislative, regulatory, local requirements
Understands procedures for safe working practice and systems of work in an industrial setting
Can read and interpret relevant engineering drawings, related specifications, quality standards and equipment manuals
Understands the hierarchy of responsibilities in relation to reporting and decision-making

Entry Skills - Expected

Practical skills in engineering assembly of a complexity consistent with that of a level 3 craftsperson
Can apply safe working practices including safe isolation to meet the requirements of statutory and non-statutory regulations
Can safely install, inspect, test, commission, diagnose and correct faults in electrical plant, instrumentation, associated cabling, cabling supports and equipment
Can select, gland & terminate industrial type cables to a suitable component and associated cable tray in line with details on the appropriate specification
Can interpret manufacturers documentation for correct installation,maintenance and inspection

Job Roles
Aspiring to or operating in

Installation or Maintenance Electrician
Electrical or Instrument Technician
Engineers

Entry Experience
Guidance

2 + years' experience operating in a site / industrial environment
Installing, inspecting, testing and/or maintaining equipment in an industrial setting

Entry Knowledge - Desirable

Understands the need for and methods of achieving safe working practice in gas and vapour Ex environments
Has basic practical, theoretical and technological knowledge and understanding of gas and vapour Ex environments
Has a basic understanding of the requirements, materials and equipment considerations, in relation to working in gas and vapour Ex environments

Entry Skills - Desirable

Can select and install a variety of Ex certified cables glands and terminate conductors into equipment
Can understand the principles of electrical protection concepts including selection, installation and maintenance
Understands intrinsically safe concept of protection and installation including the importance of documentation
Can inspect new and existing equipment in accordance with appropriate inspection techniques relevant to the different grades of inspection

Header Column #1
Industries	Principal to all Ex environments, with direct application in hazardous vapour and gas environments.
Entry Qualifications Guidance	Level 3, ECS Gold Card, National Diploma or equivalent. Disipline: Electrotechnical Instrumentation Subject to knowledge, skill and experience candidates may benefit from Ex F+
Entry Knowledge - Expected	Knows the relevant legislative, regulatory, local requirements Understands procedures for safe working practice and systems of work in an industrial setting Can read and interpret relevant engineering drawings, related specifications, quality standards and equipment manuals Understands the hierarchy of responsibilities in relation to reporting and decision-making
Entry Skills - Expected	Practical skills in engineering assembly of a complexity consistent with that of a level 3 craftsperson Can apply safe working practices including safe isolation to meet the requirements of statutory and non-statutory regulations Can safely install, inspect, test, commission, diagnose and correct faults in electrical plant, instrumentation, associated cabling, cabling supports and equipment Can select, gland & terminate industrial type cables to a suitable component and associated cable tray in line with details on the appropriate specification Can interpret manufacturers documentation for correct installation,maintenance and inspection
Job Roles Aspiring to or operating in	Installation or Maintenance Electrician Electrical or Instrument Technician Engineers
Entry Experience Guidance	2 + years' experience operating in a site / industrial environment Installing, inspecting, testing and/or maintaining equipment in an industrial setting
Entry Knowledge - Desirable	Understands the need for and methods of achieving safe working practice in gas and vapour Ex environments Has basic practical, theoretical and technological knowledge and understanding of gas and vapour Ex environments Has a basic understanding of the requirements, materials and equipment considerations, in relation to working in gas and vapour Ex environments
Entry Skills - Desirable	Can select and install a variety of Ex certified cables glands and terminate conductors into equipment Can understand the principles of electrical protection concepts including selection, installation and maintenance Understands intrinsically safe concept of protection and installation including the importance of documentation Can inspect new and existing equipment in accordance with appropriate inspection techniques relevant to the different grades of inspection