Ensuring Safety and Compliance in ATEX Environments: Gas Detection Solutions by Gas Sense
In many industries worldwide – from oil & gas and mining, to food and beverage production – hazardous substances are just part of the job. Flammable gases, vapors or dust are often present as inputs, outputs or byproducts of multiple processes; however, they can also pose significant risks to workplace safety if not managed correctly.
Gas detectors are the first line of defense against a long list of these combustible agents. Their deployment in ATEX areas is necessary for the timely detection of dangerous gas concentrations and prevention of incidents.
The following article reviews the basic principles of ATEX and how Gas Sense gas detectors can help you:
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- Prevent explosions and fires;
- Protect property and personnel;
- Ensure regulatory compliance;
- Minimize process disruptions.
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What is ATEX?
ATEX (short for "ATmosphères EXplosibles") refers to the set of European regulations that outline the requirements for equipment, designed for use in explosive environments. The first strides in ATEX regulation were made as a countermeasure to fatal incidents in industry and mining. Starting at the national level, these requirements soon transformed into continental harmonized standards. Today, they are outlined in two directives (2014/34/EU for manufacturers and 1999/92/EC for workplace safety).
According to these directives, the degree of risk is quantified based on the frequency and duration of the presence of explosive atmospheres. These measures are used to determine the design requirements for equipment and safety measures required in each zone. Below is a breakdown of the different ATEX zones:
Gas Hazard Zones
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- Zone 0 – The highest-risk classification, where an explosive atmosphere is present continuously or for prolonged periods. Gas detectors operating in these zones must provide an element of intrinsic safety (Ex ia), meaning they must not generate enough energy to cause ignition, even in fault conditions.
- Zone 1 – An area where an explosive atmosphere is expected to occur during normal operations. Gas detector protection mechanisms are typically Flameproof (Ex d) or increased safety (Ex e) to contain or prevent sparks.
- Zone 2 – In this zone, an explosive atmosphere is unlikely to occur under normal operating conditions, and if it does occur, it will only persist for a short time. Gas detectors may offer a variety of protection mechanisms, including Non-sparking (Ex n) or Flameproof (Ex d).
Dust Hazard Zones
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- Zone 20 – The highest-risk dust zone, where combustible dust is present continuously or for extended durations, creating an ongoing explosion risk.
- Zone 21 – An area where combustible dust is likely to be present occasionally during normal operations.
- Zone 22 – A lower-risk classification where a combustible dust cloud is unlikely to form, and if it does, it will only persist briefly.
Gas Detection in ATEX (Hazardous) Areas
Gas detection systems play a crucial role in mitigating the risks associated with operating in ATEX-classified environments.
While many compliant facilities are equipped with comprehensive safety systems, including heat, smoke and fire detection, the nature of these technologies limits them to a reactive solution. In other words, they can only identify the problem once it has already occurred. Gas detectors, on the other hand, offer a proactive prevention mechanism.
Many of the compounds use in industry are so volatile that they can combust in concentrations as low as 1.6vol% (C₄H₁₀). This means that a combustible mixture may become present just seconds after a gas leak. Unless the issue is handled at the source, it could very easily compound and lead to significant damage. This is how a functional gas detector could make the difference between a simple safety procedure and an unfortunate workplace incident.
Gas Sense GDPC Series ATEX Gas Detector
The GDPC line is the newest addition to the Gas Sense range of ATEX solutions. It is designed to deliver maximum flexibility and reliability in the most demanding industrial settings and features a selection of ATEX-certified fixed-point detectors (Zone 1 and Zone 0 configurations available) for combustible, toxic and refrigerant gases, as well as Oxygen level monitoring.
The GDPC Series Gas Detector features our optimized technical specs for LEL and ppm detection of the most common hazardous substances used in Oil & Gas, Chemical and Pharmaceutical Manufacturing, Power Generation and many others.
Benefits:
· Maximum Safety:
The GDPC is compliant with relevant EU standards (ATEX, EN 50270, SIL2 HW and SW in progress). The IP67-rated, explosion-proof aluminum enclosure along with the stainless steel, corrosion-resistant sensor housing and cable glands, make for stability and durability in harsh operating environments.
· Universal Compatibility:
Select between 4-20mA current, Modbus RTU, or relay/transistor outputs for versatile integration of the GDPC into existing systems or upcoming projects. Whatever the requirements, the GDPC is the one-stop solution for industrial gas detection.
· Ease of Use:
Our proprietary TouchCal non-intrusive calibration procedure is streamlined, error-proof and requires no external devices. The calibration of GDPC detectors is incredibly simple and performed by one person via magnetic key. This eliminates the need for hot work and minimizes system downtime. Solderless sensor replacement and pre-calibrated sensor options available. Select between an OLED display or our signature high-visibility status LED to optimize fieldwork depending on your application.
· Sensor Options:
At the core of the GDPC ATEX Gas Detector are the most established sensor technologies for ppm and LEL combustible substance detection, including the catalytic, NDIR and electrochemical sensors, as well as the industry-leading MPS™ by Nevada Nano.
The revolutionary technology behind the MPS™ sensor allows for a 10+ year lifetime with a zero field calibration requirement, poison immunity and continuously accurate readings, regardless of environmental conditions. These features ensure unmatched reliability in hydrogen detection across the most demanding industrial environments.
What makes the MPS™ sensor truly remarkable is its ability to detect a multitude of flammable gases—including hydrogen, methane, propane, and acetylene—simultaneously, without a risk of false alarms or long-term performance degradation.
Learn more about the GDPC ATEX Gas Detector and the technology that powers the MPS™ sensors. Ensuring compliance with ATEX regulations and deploying reliable gas detection systems significantly reduces the risk of explosions in hazardous workplaces. By understanding classifications, using certified equipment, and maintaining robust safety protocols, businesses can safeguard both personnel and assets.
Contact us to learn more about our comprehensive range of gas detection solutions.
Gas Sense – Precision in Protection.
References:
1. European Commission – ATEX Directive (2014/34/EU)
Official EU regulations on equipment used in explosive atmospheres.
Available at: https://ec.europa.eu/growth/sectors/mechanical-engineering/atex_en (Accessed: 30 January 2025).
2. International Electrotechnical Commission (IEC) – IEC 60079 Standards
Global standards for electrical equipment in explosive atmospheres.
Available at: https://www.iec.ch/homepage (Accessed: 30 January 2025).
3. National Institute for Occupational Safety and Health (NIOSH) – Flammable Gas and Vapor Safety
Research and recommendations on gas detection and explosion prevention.
Available at: https://www.cdc.gov/niosh (Accessed: 30 January 2025).
4. European Committee for Standardization (CEN) – EN 60079 Series
European safety standards for explosive atmospheres, aligned with IEC regulations.
Available at: https://www.cencenelec.eu (Accessed: 30 January 2025).
5. MPS™ Hydrogen Gas Sensor (2023) NevadaNano.
Available at: https://nevadanano.com/mps-hydrogen-gas-sensor/ (Accessed: 30 January 2025).