Ex zones are clearly demarcated areas in which an explosive atmosphere in the form of a cloud of flammable substances contained in the air occurs continuously or for long periods. This means that flammable substances are manufactured, processed, transported or stored in these environments and air comes into contact with flammable substances in the form of gases, vapors or mist.
In order to be able to work safely in these areas despite the numerous sources of danger, there are various legal requirements. The aim is to optimize explosion protection at work and prevent accidents at work. The division into different Ex zones helps to classify the risks and to define and implement appropriate protective measures.
The implementation of suitable protective measures in Ex zones requires close cooperation between explosion protection specialists, occupational safety experts and the employees on site.
This involves implementing specific technical solutions such as explosion-proof electrical equipment, appropriate ventilation systems and regulations for handling flammable materials. This collaboration is essential to ensure that safety standards in Ex zones are met at all times and the risk of explosions is minimized.
The most important facts in brief
✓ Ex zones classify explosion hazards due to flammable substances in the air and require special safety measures such as explosion-proof equipment and ventilation systems.
✓ ATEX zones are special Ex zones according to EU directives that prescribe strict safety requirements and equipment, including risk assessments and explosion protection documents.
✓ Ex zones are relevant in many industries, e.g. in the chemical, oil and gas, pharmaceutical, food and automotive industries. CALIMA can be used in these areas with suitable explosion-proof smartphones.
What Ex zones are there?
Zone 2 or Zone 22
As a rule, explosive atmospheres do not occur in Zone 2 or 22. And if they do, then only rarely and only for a short time. Although the risk of explosion in these zones is very low, electrical equipment and other potential sources of ignition must be designed in such a way that they cannot cause an explosion under any circumstances.
This ensures that maximum safety is guaranteed even in the event of unexpected incidents or malfunctions in these zones. Zone 2 or 22 can, for example, be located near tanks in which flammable substances are stored.
Zone 1 or Zone 21
Zone 1 or Zone 21 is an area in which an explosive atmosphere in the form of a cloud of flammable substances contained in the air may occasionally occur. An explosion can occur here both during normal operation and in the event of malfunctions. Due to the increased risk of explosion, special precautions must be taken in these areas.
Electrical equipment and other potential sources of ignition must be explosion-proof to ensure the safety of employees. Regular inspections and maintenance are essential to ensure that the protective measures work reliably. Zone 1 or 21 could therefore exist when handling solvents.
Zone 0 or Zone 20
In Zone 0 or Zone 20, an explosive atmosphere is constantly present for long periods of time. This is where the risk of explosion is greatest. In these zones, all electrical equipment and other potential ignition sources must be explosion-proof. The safety standards in these areas are particularly high in order to keep the risk of explosion as low as possible.
In addition to the technical measures, comprehensive training of employees is crucial here in order to develop a deep understanding of the risks and respond appropriately. Zone 0 or 20 is generally only located inside systems or system components, such as evaporators, reaction vessels, dust filters, etc.
What is the difference between an Ex zone and an Atex zone?
The main difference between an Ex zone and an ATEX zone is that the Ex zone stands for explosive atmospheres in general, while ATEX zones refer more specifically to the European directives regulating these zones. Ex zones are potentially explosive areas that are divided into ATEX zones depending on the degree of danger.
The probability of the occurrence of explosive atmospheres is examined as part of a risk analysis and requirements are set for workplaces in potentially explosive atmospheres. The requirements are set out in the ATEX Directive.
The ATEX zone is therefore a specific Ex zone that meets the explosion protection requirements of the ATEX Directive applicable in the EU. ATEX is the French abbreviation for Atmosphère Explosible.
In addition to European standards and regulations, international standards are also taken into account for the Ex zone, as this is a general term. While the ATEX zones are recognized in Europe, other standards may apply in other countries.
Companies operating in different regions must therefore pay close attention to the respective regulations and standards to ensure that they comply with safety standards.
Legal basis
Directive 99/92/EC (ATEX 137), also known as the ATEX Directive, is of great importance in Europe, as it regulates explosion protection in potentially explosive atmospheres and specifies requirements for devices and protective equipment that may be used in these areas.
For example, hazardous areas must be marked with warning signs and special personal protective equipment must be worn. The standard refers to Article 137 of the European Treaty to ensure the protection of workers.
Directive 99/92/EC also describes the obligations of the plant operator. This includes carrying out a risk assessment in the plant, which serves as the basis for classification into ATEX zones. On the basis of the defined zone, the plant operator must then ensure that suitable occupational health and safety measures are implemented. This obligation of the operator also arises from Section 5 of the Occupational Health and Safety Act.
Accordingly, every employer must carry out a risk assessment to determine the hazards associated with the employees' work and assess the working conditions. In accordance with Section 6 (9) of the Hazardous Substances Ordinance (GefStoffV), suitable protective measures must be taken and documented in an explosion protection document.
The ATEX Directive applies in the EU member states that have transposed it into national law. Furthermore, some member states may introduce additional requirements or supplementary directives in order to take better account of specific national circumstances or industry needs.
Plant operators must therefore ensure that, in addition to the ATEX Directive, the requirements of occupational health and safety in conjunction with national legislation are also met in potentially explosive atmospheres.
In Germany, for example, DIN EN 60079-10-1 is the national standard for explosion protection in potentially explosive atmospheres. This standard defines the zoning and the protective measures required to keep the risk of accidents as low as possible.
In which industries are Ex zones required?
Ex zones are required in areas where flammable substances are present or may arise. These substances can be gases, vapors, mists or dusts. In certain industries, these substances are often present in the workplace.
Chemicalindustry : When working in the chemical industry, flammable gases, vapors and liquids often create a hazardous explosive atmosphere. There may be Ex zones in production, storage and filling facilities.
Oiland gas industry: A hazardous explosive atmosphere occurs in particular during the exploration, extraction, processing and storage of crude oil and natural gas. Drilling rigs, refineries, tank farms and pipelines are typical areas with Ex zones. Here, protection against explosions is crucial to ensure the safety of employees and the integrity of the facilities.
Pharmaceuticalindustry: Flammable substances are often used in the manufacture of medicines and other pharmaceutical products. Production facilities, laboratories and clean rooms are therefore Ex zones. In this sensitive industry, explosion protection is essential to ensure the quality of the products and minimize the risk of disruptions in the manufacturing processes.
Food industry: Dust or vapors that form a hazardous explosive atmosphere can also arise during the processing of food. Examples of companies with hazardous areas are mills, breweries and bakeries. In the food industry, protection against explosions is not only important for the safety of employees, but also for the quality and consistency of the products manufactured.
Mining: Dust or gases can also be generated during the processing of raw materials, resulting in a hazardous explosive atmosphere during normal operation. Typical companies with hazardous areas are mines, quarries and opencast mines. Explosion protection is of great importance here in order to protect the health of miners and minimize the risk of serious incidents underground.
Automotive industry: There are Ex zones in the automotive industry, particularly in paint shops and paint booths. The use of flammable paints and solvents poses a potential explosion risk. Explosion protection measures are therefore crucial to ensure the safety of workers in these areas.
Energy industry: Power plants, both conventional and renewable energy plants, can have Ex zones. Flammable materials such as coal dust or methane gas may be present in these plants. Protection against explosions is essential in the energy industry to ensure continuous and safe operation.
Can CALIMA be used in Ex zones?
Yes, CALIMA can function and be used in an EX-protected area. The prerequisite for this is that CALIMA is installed on smartphones with an Android operating system that are suitable for use in potentially explosive atmospheres. An example of a suitable device is the I.SAFE(https://www.isafe-mobile.com/de/produkte).
