Direct answer
For flammable liquids, vapours or combustible dusts, the site must assess dangerous substances and explosion risk under DSEAR. Hazardous zones and the equipment located in or connected to them should be defined by competent people before machinery is specified. ATEX equipment selection is one part of the complete control strategy, not a substitute for preventing or controlling the atmosphere.
Key takeaways
- Identify dangerous substances and credible release scenarios.
- Classify hazardous areas and define control measures.
- Specify and verify the complete installation.
- Manage changes and preserve explosion protection.
Establish the legal and technical scope
Use current safety data, process conditions, quantities, temperatures, transfer methods, cleaning and abnormal events. Powders can create combustible dust risk even when the normal product is not described as flammable.
- List substances and relevant physical properties
- Map filling, transfer, venting and cleaning releases
- Include waste, spills and residues
- Consider dust layers and secondary explosions
Assess the actual machine, task and site
Competent assessment should define the location, extent and duration of explosive atmospheres and the equipment category required. Prioritise elimination, substitution, containment and ventilation before relying on ignition protection.
- Produce zone drawings and equipment boundaries
- Review ventilation and extraction
- Control static electricity and bonding
- Assess hot surfaces, sparks and mechanical ignition
Create and retain suitable evidence
Record equipment certificates, markings, temperature classes, gas or dust groups, installation requirements, earthing, ventilation and interfaces. Non-electrical equipment and connected systems also need consideration.
- Hazardous-area assessment and zone plan
- Equipment schedule and certificates
- Installation and earthing test evidence
- Inspection, maintenance and training records
Keep the control current
Product concentration, temperature, throughput, extraction, cleaning chemicals, replacement components and layout can change the assessment. Maintenance should use suitable parts and competent inspection.
- Review after product or process change
- Control replacement equipment and repairs
- Inspect extraction and earth continuity
- Keep emergency arrangements and training current
Comparison table
| Control area | Key question | Typical evidence |
|---|---|---|
| Scope | Identify dangerous substances and credible release scenarios. | Applicable legislation, standards and responsibility |
| Assessment | Classify hazardous areas and define control measures. | Risk assessment and verified safeguards |
| Records | Specify and verify the complete installation. | Drawings, declarations, tests and training records |
| Review | Manage changes and preserve explosion protection. | Change control, inspection and periodic review |
Free working templates
Download these files and adapt them to the actual machine, product, site and acceptance plan.
Official guidance and further reading
These sources provide the current regulatory or standards context. Always check the latest version before making a compliance decision.
Related buyer guides and tools
Relevant machinery and support routes
Use the guide to define the requirement, then compare the specialist routes below against representative product, packaging and output evidence.