Mechanical ATEX verification of several petrochemical plants

For several chemical sites in Flanders, Prohead Engineering carried out an in-depth mechanical ATEX verification of a wide range of rotating equipment. The assignment was part of the drive towards full ATEX compliance for both existing installations and recently added equipment in hazardous areas.

The focus was on mechanical ignition sources such as friction, elevated surface temperatures and static discharges. To map these hazards thoroughly, an Ignition Hazard Analysis (IHA) was carried out. This analysis served as the basis for both the inspection plan and the risk action plan for each installation.

A significant efficiency gain was achieved by using Prohead Engineering typicals — predefined inspection templates for specific types of equipment such as fans, pumps or mixers. This approach considerably shortened inspection time and ensured a uniform, reproducible analysis of similar assets.

In addition, insulation measurements were carried out to evaluate the electrical integrity of motors within Ex zones, ruling out any risk of flashover, thermal hotspots or unintended voltage build-up.

Prohead Engineering compiled a concrete, action-oriented verification file, including redline mark-ups, summary tables and visual inspection results. The recommendations were brought together in a manageable action plan that could be followed up by the in-house maintenance team and the E&I team.

Thanks to this systematic approach, not only were the requirements of ATEX 2014/34/EU and relevant regional regulations met, but the maintenance process was also optimised and staff safety improved. Moreover, this methodology provides a scalable framework that can be applied to other sites within the same group.