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What is the ATEX compliance checklist for refinery installations?

ATEX compliance at a refinery or process plant involves ten interconnected areas. Missing any one of them creates an audit finding or, worse, an unsafe installation. This checklist covers all ten.

How to use this checklist

This checklist is structured for specifying engineers, project managers, and safety managers working on new installations, major modifications, or compliance reviews of existing plant. It covers the ten areas that regulatory inspectors (HSE in the UK) and insurance auditors examine most closely.

Each item includes the specific evidence or action that demonstrates compliance. "Yes, we do that" is not sufficient, the evidence must exist and be retrievable.

1. Zone classification documents

  • An Explosive Atmosphere Document (EAD) exists, is dated, and is signed by a competent person
  • Area classification drawings exist for all areas of the installation where explosive atmospheres may form
  • Drawings show zone type, extent, and the gas/dust group and temperature class for each zone
  • Drawings are to scale and include both plan and section views where relevant
  • Documents are version-controlled with a revision history
  • The EAD references the relevant standards used (EN 60079-10-1 for gas; EN 60079-10-2 for dust)
  • The EAD and drawings have been reviewed following any process or layout change

2. Equipment verification

  • An equipment schedule exists listing all ATEX-certified equipment installed in hazardous areas
  • For each item: manufacturer, model, certificate number, zone location, and installation date are recorded
  • The equipment category and zone suitability have been verified against the area classification
  • The gas group on the certificate matches or is more stringent than the gas group in the zone
  • The temperature class (T class) is verified against the auto-ignition temperature of the substance
  • Certificates and Declarations of Conformity are held on file for all installed equipment
  • Any 'X' suffix certificates have been reviewed and the Specific Conditions of Use are implemented

3. Nameplate markings

  • All installed equipment carries legible ATEX nameplates with ⟨Ex⟩ / ⟨UK Ex⟩ marking
  • Nameplate marking strings match the certified protection concept in the application (e.g., Ex eb IIC T6 Gb in a Zone 1 IIC area)
  • Nameplates have not been painted over, corroded beyond legibility, or removed
  • Where nameplates are inaccessible for routine inspection, photographic records exist
  • IP rating is marked and visible

4. Initial inspection

  • Initial inspection records exist for all hazardous area electrical equipment (IEC 60079-17)
  • Records show that inspection was carried out before the installation was energised
  • Inspection was carried out by a competent person (demonstrable training or qualification)
  • Records include verification of gland types, IP integrity, terminal torques, and labelling
  • For intrinsically safe loops: initial inspection includes loop parameter verification
  • Any deficiencies found at initial inspection are closed out with dated evidence

5. Installation quality

  • Cable glands are certified to the same protection concept as the enclosure (Ex e glands in Ex e enclosures; Ex d glands in Ex d enclosures)
  • All unused entries are fitted with certified blanking plugs
  • Cables are correctly supported to prevent mechanical stress on gland seals
  • Conduit sealing boxes (stopping boxes) are correctly installed at Ex d enclosure entries where conduit is used
  • Terminal tightening torques are within the range specified on the certificate; records of torque settings exist where required
  • IS wiring is segregated from non-IS wiring and identified with blue colour coding or labelling
  • Earth connections are in place and correct (particularly Zener barrier earth continuity ≤ 1 Ω)

6. Maintenance regime

  • A written maintenance programme for ATEX equipment exists with inspection intervals defined
  • Inspection intervals are based on zone, environment, and manufacturer recommendations (IEC 60079-17 Table 1 as a minimum basis)
  • Periodic inspection records are maintained showing date, inspector, scope, and findings
  • Gasket condition is checked during periodic inspections; replacement schedules exist for high-UV or high-chemical-exposure locations
  • Replacement parts (glands, blanks, gaskets, fasteners) are held in stock and are certified to the correct protection concept
  • Maintenance personnel are trained in ATEX requirements and aware of restrictions on working on live equipment in hazardous areas

7. Management of change

  • A formal management of change (MoC) process exists that includes ATEX review as a standard step
  • Process changes trigger a review of whether zone classification is affected
  • Equipment changes (including like-for-like replacements) are verified against the installation zone and gas group
  • Modified intrinsically safe loops are re-calculated and documented before re-energisation
  • Area classification drawings and equipment schedules are updated as part of MoC closure
  • Changes are subject to initial inspection before energisation

8. Training records

  • Responsible persons for ATEX equipment can demonstrate competence (COMPEX or equivalent, or documented in-house training programme)
  • Training records are maintained for all personnel working on ATEX installations
  • Refresher training intervals are defined and adhered to
  • Contractors working in hazardous areas have received appropriate ATEX awareness induction
  • A competent person is identified and available for zone classification review and equipment assessment

9. Internal audits

  • An internal ATEX audit programme exists with defined frequency
  • Audit scope covers area classification documents, equipment compliance, installation condition, and maintenance records
  • Audit findings are tracked to closure with responsibility and target dates assigned
  • Previous audit findings are reviewed at subsequent audits for recurrence
  • Audit reports are retained and available for regulatory or insurance inspection

10. Documentation control

  • All ATEX documents (EAD, area classification drawings, equipment schedules, certificates, inspection records) are under document control with version management
  • Current versions are accessible to relevant personnel; superseded versions are archived but not destroyed
  • Documents are retrievable within a reasonable time (typically 24 hours for a regulatory request)
  • A document owner is assigned for each ATEX document type
  • The document retention period meets the legal minimum (typically 10 years post-decommissioning)
Common questions

Frequently asked

What documentation is required for ATEX compliance?

ATEX compliance requires: area classification drawings showing zone boundaries, an Explosion Protection Document (EPD) under ATEX Directive 1999/92/EC, an equipment register listing each item of ATEX-certified equipment with certificate numbers, initial inspection records to IEC 60079-17, and maintenance records showing ongoing inspection at defined intervals. For new installations, a commissioning inspection report is required before energisation.

How often must ATEX equipment be inspected?

IEC 60079-17 defines four inspection grades: visual, close, detailed, and sample. Frequency depends on the environment, zone, and equipment category. In practice, visual inspection is typically annual, close inspection every 1–3 years, and detailed inspection every 3–5 years. The duty holder must document the inspection schedule and retain records as part of the Explosion Protection Document.

What is an Explosion Protection Document?

An Explosion Protection Document (EPD) is a written record required by ATEX Directive 1999/92/EC that demonstrates the duty holder has assessed explosion risks, classified hazardous areas, identified measures taken to prevent and protect against explosions, and assigned responsibilities. It must be prepared before any work in hazardous areas begins and kept up to date whenever the plant or zone classification changes.

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