ATEX explosion protection – design, inspections and audit (gas & dust)
Safety, compliance and reliability in one hand.
Our services are based in Kecskemét and Bács-Kiskun County, available nationwide and for international industrial projects as well.
Area classification, Explosion Protection Document (EPD), Ex equipment selection, installation support and periodic inspections – to EN/IEC 60079.Online ATEX consultation – for smaller questions and quick decisions
Sometimes you “just have a few ATEX questions”, but the project is not yet at the stage where a full Explosion Protection Document or a larger design assignment would make sense.
For these cases I created the online ATEX consultation packages, where you can get fast, practical expert input by e-mail and online meeting, with clear pricing – starting from HUF 19,900 (introductory price).
- “Quick ATEX question” – one focused topic answered by e-mail
- 1 day of online ATEX support – intensive Q&A and drawing review
- 1 week of project-preparation support – for new or changing installations
International experience – real industrial background
Not always clear who is responsible for what in ATEX (operator, designer, contractor, authorities)? I’ve summarised it on a dedicated page: ATEX Knowledge Base – Who does what?.
My mission and approach
My goal is to help owners and operators achieve legal and technical ATEX compliance through practical, cost-effective solutions – based on current standards and hands-on industrial experience.
- Partner mindset: I act not as an inspector but as a solution-focused engineering partner.
- Modern methods: current ATEX/IEC standards, proven engineering practice, transparent documentation.
- Works in the field: area classification, EPD, equipment selection, installation support and inspections – designed to work in real-world operation.
- Gas (IIA/IIB/IIC) and dust (IIIA/IIIB/IIIC) environments
- Area classification, EPD, periodic inspections (IEC 60079-17)
- E&I + HVAC compliance, construction supervision
I have over 25 years of experience in electrical and HVAC systems, including 17 years in the oil & gas industry across offshore and onshore environments.
- TotalEnergies / Maersk – Gorm Offshore Platform (Denmark) – electrical systems (33 kV – 400 V), ATEX inspections, maintenance and permit responsibility.
- TengizChevrOil – FGP-3GP (Kazakhstan) – Preservation / Electrical Lead Engineer.
- ExxonMobil – Berkut Offshore (South Korea) – E&I + HVAC engineering.
- ExxonMobil – Orlan (Sakhalin) – Arctic offshore platform supervision.
- AGIP KCO / NCOC – Karabatan (Kazakhstan) – EHT and ATEX oversight.
- Bechtel / Enka – Tengiz expansion – HVAC and electrical construction QA/QC.
Standards: IEC 60079, NFPA, IEEE, ASHRAE. – Certification: CompEx – ATEX.
What is ATEX? – two main EU directives
ATEX is the European framework for explosion protection (from the French ATmosphères EXplosives). It is built around two main directives:
-
2014/34/EU – “ATEX Equipment Directive” (ATEX 114)
Applies to manufacturers, importers and distributors. It defines how equipment and protective systems intended for use in explosive atmospheres must be designed and certified. -
1999/92/EC – “ATEX Workplace Directive” (ATEX 137 / ATEX 153)
Applies to the employer / operator. It sets requirements for explosion risk assessment, zoning, selection of suitable equipment, explosion protection documentation and training.
In ATEX there are two main responsibility areas:
- the manufacturer / distributor is responsible for properly certified Ex equipment,
- the operator is responsible for using it in the right place and in the right way, safely.
Employer / operator obligations (Hungary – Decree 3/2003. (III. 11.) FMM–ESzCsM)
In Hungary, the 1999/92/EC ATEX Workplace Directive is implemented by Decree 3/2003. (III. 11.) FMM–ESzCsM on the minimum safety requirements for workplaces where explosive atmospheres may occur.
Practical translation: as soon as a plant stores or uses any flammable gas, vapour, mist (aerosol) or combustible dust, the employer is obliged to assess whether an explosive atmosphere may be present – i.e. whether the workplace qualifies as a “potentially explosive atmosphere” under this decree. If the answer is yes, the decree becomes fully applicable and explosion protection is not optional, but a legal requirement.
- assessment of explosion risks,
- classification of zones (0/1/2, 20/21/22),
- preparation of an Explosion Protection Document (EPD – in Hungarian practice often called RVD) before first commissioning,
- definition and implementation of the necessary technical and organisational measures (ventilation, earthing, procedures, permit-to-work, training, etc.),
- keeping the RVD/EPD up to date (whenever technology changes and, in practice, reviewing it at least every 3 years).
The RVD/EPD and the associated zoning drawings may be requested by the authorities (labour inspection, disaster management) at any time during an inspection, and they may also verify on site whether the measures described in the document are actually in place.
Typical introductory sentence in an Explosion Protection Document:
“This document constitutes the Explosion Protection Document (hereinafter: RVD/EPD) for the potentially explosive areas of the plant, prepared in accordance with Decree 3/2003. (III. 11.) FMM–ESzCsM.”
How does the process start in practice?
- A flammable substance appears – e.g. solvent, alcohol, flour dust, sugar dust, biogas, dusty process.
- A risk assessment is carried out to determine whether an explosive atmosphere may form and where.
- If yes, the workplace is considered a potentially explosive atmosphere, the 3/2003 decree applies, and the RVD/EPD becomes a mandatory safety document.
- The employer – typically with the help of an expert – prepares the RVD/EPD and ensures that training, permit-to-work, maintenance and modifications are aligned with what is written in the document.
Note: the information above does not constitute legal advice. The aim is to provide a clear, practical overview of the main obligations for operators dealing with explosive atmospheres.
For a more detailed, law-focused explanation, see the ATEX Knowledge Base – What is ATEX? page.
How FullCare supports your obligations
The obligations above are not “nice-to-have paperwork” but legal duties of the employer. This is where I can help you with practical, engineering-level support:
- Explosion risk assessment for both gas (G) and dust (D) atmospheres.
- Area classification (zones 0/1/2 and 20/21/22) with zoning drawings.
- Preparation or update of the Explosion Protection Document (RVD/EPD) for new and existing plants.
- Definition of technical measures: ventilation, earthing and bonding, detection, Ex equipment selection.
- Review and creation of operational procedures (permit-to-work, maintenance rules, training content).
- Periodic ATEX inspections to IEC 60079-17 with photo-documented, prioritised defect lists.
If you already have an EPD, I can review your existing documentation and zoning
and give a clear status on how it aligns with current requirements.
Start with a free online needs assessment →
Area classification – gas & dust
Gas / vapour (G)
| Zone | Description | Example |
|---|---|---|
| 0 | Explosive gas mixture present continuously or for long periods | Inside tanks |
| 1 | Likely to occur in normal operation | Filling points |
| 2 | Not likely and if so only short-term | Valves, flanges |
Groups: IIA / IIB / IIC
Dust (D)
| Zone | Description | Example |
|---|---|---|
| 20 | Continuous/long-lasting dust cloud | Inside silo, cyclone |
| 21 | Frequently occurring dust cloud | Packing, discharge points |
| 22 | Occasional dust cloud | Around conveyors |
Dust groups: IIIA (fibres) · IIIB (non-conductive) · IIIC (conductive)
Our services – end-to-end
1) Site survey & zoning
Hazard sources, ventilation, leakage points, dust deposits; zone boundaries and drawings.
2) Explosion Protection Document
EPD, ignition source analysis, static electricity, operating rules, training syllabus.
3) Equipment selection & compliance
Ex equipment specs, cable glands and stopping plugs, bonding/earthing and EPB; certificate checks.
4) Installation support
Construction inspections, punch lists, pre-commissioning conformity checks.
5) Periodic inspections
Visual / close / detailed (IEC 60079-17) with prioritised defect list and photo records.
6) Training
ATEX fundamentals/advanced, maintenance and operations targeted trainings.
Typical industries
Grain & feed (silos, elevators), food & wood (sugar, flour, sawdust), chemicals/solvents, oil & gas / biogas / wastewater (CH₄, H₂S), pharmaceuticals.
Common issues we fix
- Insufficient IP/dust-tightness (Ex t enclosures leakage)
- Missing/wrong stopping plugs, non-Ex cable glands
- Incorrect earthing and bonding (parallel PE, ground loops)
- Wrong temperature class (T-class vs. ignition temperature)
- Wrong gas/dust group (IIB ↔ IIC; IIIB ↔ IIIC)
- Undocumented modifications, outdated EPD
Process
Step 0 – Free online needs assessment (30–60 minutes)
The first step is that you reach out via the website (by e-mail or contact form). We then schedule a 30–60 minute online call (phone / Teams / WhatsApp / Viber) where we:
- discuss your site, process and typical hazard sources,
- review which ATEX / EPD documents (if any) already exist,
- clarify what you actually need in practice – and at what depth.
Typical levels of engagement:
- Consulting – professional advice, Q&A, direction-setting.
- Design / review & documentation update – zoning drawings, EPD, review and update of existing documentation.
- Implementation support – reviewing equipment lists and offers, supervising implementation, handover and training.
The call is free of charge, and by the end we have a shared understanding of whether an on-site survey is justified and which package fits best. Based on this, I provide a concrete written quote for the next step.
- Pre-screen / consultation – photos, layouts, process description
- On-site survey – sampling, measurements, interviews
- Zoning drawings & EPD – standards-compliant document set
- Compliance plan – equipment list, BOM, cost estimate
- Implementation support – inspections, handover, training
- Periodic audit – annual / 3–5-year detailed cycles
Packages
Starter – Quick pre-screen
1 site · up to 1 day on site · risk focus list · preliminary zoning · recommendation notes
Request a quote by emailPro – Full compliance
Detailed zoning drawings, EPD, inspection reports, operator training
Request a quote by emailEnterprise – Multi-site
Multi-day on-site work, scheduled reviews, KPI reports, annual audit & re-cert
Request a quote by emailWe also provide a printable checklist (G/D) – ask by email.
Frequently Asked Questions
Why is there no phone number listed?
Therefore, email / online contact is my preferred first channel of communication. After arranging a time by email, I am of course available for phone or online calls as needed.
Do you also carry out installation work, or only documentation and inspection?
Will I receive an official report or certificate after the inspection?
When is it mandatory to prepare or update the Explosion Protection Document (EPD)?
What is the difference between gas (G) and dust (D) explosion protection?
What does the marking “Ex tD A21 IP6X” mean?
Ex t IIIC T… Db IP…,
where IIIC specifies the dust group and Db the Equipment Protection Level.
When is the periodic ATEX inspection mandatory?
How long does a site inspection and documentation take?
Note: explosion protection is not a “one-time task” – it’s a continuous process. Whenever processes, layouts or equipment change, compliance must be reviewed and updated. Subscription-based clients benefit from annual schedules and automatic reminders to maintain full compliance.
Do you offer subscription or framework-agreement support?
- Priority scheduling for inspections and consultations
- Planned periodic reviews (annual / 3–5 year cycle) with expiry reminders
- Discounted hourly / daily rates and fixed pricing for key services
- KPI reports showing progress, corrective actions and compliance trends
- Direct contact with István for fast professional phone or online support