Why, When, and Where Do You Need an ATEX Drum Pump?
ATEX (Ex) products are required in environments where there is a risk of explosive atmospheres being present. ATEX stands for Atmosphères Explosibles, the French term for explosive atmospheres. Industries such as oil and gas, petrochemical, pharmaceuticals, mining, chemical processing, agriculture, waste treatment and food processing often contain hazardous zoned areas. This is where an ATEX drum pump plays a critical role.
The need for an ATEX drum pump arises due to safety concerns. Explosive atmospheres may form when flammable gases, vapours, mists, or combustible dusts mix with air in a ratio can ignite upon contact with an ignition source. Typical ignition sources include: a discharge of static electricity, naked flames, or sparks created during hot works. To prevent accidents and protect the safety of workers in such environments, use ATEX drum pumps in these areas.
Typical applications for an ATEX drum pump include storage, mixing, and transfer of paints, solvents and fuels, where flammable gases or vapours exist. Dust generating activities such as metal machining, sanding, storing foodstuffs and agricultural fertiliser can also create explosive dust-air mixtures that also require ATEX equipment.
The ATEX Directives mandate the use of ATEX products. These European Union (EU) Directives outline essential safety requirements for equipment and protective systems used in explosive atmospheres. Furthermore, the Directives have been widely adopted as a globally recognised safety standard. However, certain regions, such as the United States, have their own standards.
The ATEX Directives are complex and as such, please seek specialist advice before pumping, mixing, filtering and filling flammable liquids. Give extra consideration to liquids exhibiting lowconductivity (due to slow electrostatic charge dissipation) and / or low flash points.
What is the ATEX Directive 2014/34/EU?
The ATEX Directive 2014/34/EU stipulates design features and recommendations that equipment manufacturers must include, to reduce explosion risk and contain an explosion, if equipment fails. The standard ensures that manufacturers apply the correct design criteria and testing to prove their equipment qualifies for Ex approval. Equipment that is compliant with the ATEX Directive has a CE mark and red Ex marking.
Additional markings create a code, which describes the suitability of the equipment for use in different environments and atmospheres, taking into consideration factors such as surface temperature, above or below ground use and zoned area category.
The aim of the ATEX Directive
The Directive aims to ensure that manufacturers design and manufacture equipment for explosive atmospheres in a safe, logical, standardised way, that reduces or eliminates the risk of explosion and ensures that a flash fire is contained within the equipment. This guarantees that a fire or explosion cannot spread further. Equipment manufacturers employ zone separation methodology to their designs, for this purpose. Electrical components and machinery with moving mechanical parts that could create heat or sparks, for instance, if a malfunction occurs, must comply with the Directive. Such equipment includes pumps, electric motors, compressed air motors and valve actuators.
Equipment without moving parts, such as hoses, pipework and couplings, do not require certification under the ATEX Directive because they typically cannot malfunction, or generate enough energy to cause heat or sparks. Some items are classed as intrinsically safe and as such, they do not require certification under ATEX. However, items such as hoses and fittings must be certified as being conductive. Otherwise there is a risk of electrostatic charge build-upon such items, which could result in a spark if static electricity is suddenly discharged, for example, by connecting a non-conductive hose to an unearthed pump.
What are typical ATEX products?
ATEX products encompass a wide range of equipment, including but not limited to:
Electrical equipment: eg. switches, sensors, lighting fixtures, motors, control panels, and other electrical devices.
Mechanical equipment: eg. pumps, compressors, fans, mixers and other rotating machinery.
You require ATEX certified products once qualified assessors complete a Zoned Area Classification exercise, to determine the extent of each hazard zone (classified as either 0, 1 or 2). In the UK, this exercise may involve a DSEAR risk assessment. Once the extent of the zoned areas are determined, choose equipment with the appropriate ATEX designation and certification. However, also consider specific environmental factors when selecting equipment.
Here are some scenarios where ATEX products are typically essential:
Petrochemical Industry: Oil refineries, petrochemical plants, offshore platforms and other facilities involved in the extraction, processing, and storage of flammable fuels and highly flammable solvents.
Chemical Industry: Chemical and fertiliser manufacturing plants, laboratories and facilities where workers handle flammable chemicals or reactive substances.
Mining Industry: Mines may contain potentially explosive gases or dust, making ATEX approval vital for mining equipment, underground lighting, ventilation and mineral processing facilities.
Pharmaceutical Industry: Processes within the pharmaceutical industry may involve flammable or explosive substances eg. preparation and mixing of alcohol gels.
Food and Beverage Industry: Facilities that produce combustible dust/air mixtures, such as grain silos or flour mills. Distilleries where flammable vapours are present.
Waste Treatment and Recycling: Waste treatment tanks, composting sites, biological treatment facilities and recycling centres may produce flammable gases or dust.
What is DSEAR?
DSEAR stands for The Dangerous Substances and Explosive Atmospheres Regulations 2002. This regulation requires employers in the UK to control risks to safety from fire, explosion and substances that are corrosive to metals. DSEAR risk assessments therefore go hand in hand with Zoned Area Classification and ATEX equipment considerations.
Definition of Zoned Area Classification
The specific requirements for ATEX products partly depend on the zone classification, which categorises areas according to the likelihood and duration of the presence of explosive atmospheres. The classifications are Zone 0, Zone 1, Zone 2 for gases and vapours, and Zone 20, Zone 21, Zone 22 for dusts. The lower the zone classification number, the higher the chance of an explosive atmosphere being present.
What is a certified ATEX drum pump?
An ATEX drum pump is certified to operate in potentially explosive atmospheres. Flux Pumps specifically designs our ATEX pumps (and their motors) to prevent ignition of flammable gases and vapours. Note, however, that Flux Pumps are not certified for use in areas containing explosive air-dust mixtures.
Consideration is given to potential malfunction of a pump or drive motor, which may cause excessive heat to be generated. Industries such as petrochemicals, pharmaceuticals, chemicals and mining commonly use an ATEX drum pump. This is due to a high risk of explosive atmospheres being present during dispensing, mixing and transfer of flammable fuels or solvents.
To meet ATEX standards, pumps undergo rigorous testing and must comply with strict safety requirements. The pumps are constructed from electrically conductive materials that reduce the risk of electrostatic charge build-up and spark, or heat generation. Electrical components, such as motors and switches, use flame-proof enclosures that can contain a flash fire. Additionally, they utilise intrinsically safe components wherever possible. Additionally, ATEX pumps incorporate safety features including earth bonding points, explosion-proof enclosures, flameproof gaskets and sealed cable glands.
When should you use an ATEX drum pump?
Follow some simple guidelines:
The pump is used in a zone 0, 1 or 2 area (as determined by Zoned Area Classification or DSEAR risk assessment).
Pumping flammable liquids with flash point below 50 deg C.
Pumping low-conductivity flammable liquids (due to slow dissipation of electrostatic charge), particularly liquids with low flash point.
Note you still require an ATEX certified pump when pumping non-flammable liquid inside a Zoned area. Flux pumps are not suitable for use in Zone 20, 21 or 22 flammable dust hazard areas.
When pumping flammable liquids, please consider:
High flow rates, filtration, separation and mixing increase electrostatic charge in liquids, which raises the risk of creating a spark.
Avoid splash-filling vessels if possible, due to creation of excess vapour.
Small bore pipes, bends and valves can increase electrostatic charge.
Earth bonding requirements
Hoses and fittings must be conductive and certified. This is to ensure that electrostatic charge can be dissipated effectively and to eliminate any electrical potential differences between components in the pumping system.
What options are available for an ATEX explosion proof pump?
At Flux Pumps, we produce a range of Ex drum and barrel pumps and air-operated double diaphragm pumps, identified by the red Ex symbol. You can use these pumps in Zone 0, 1 and 2 areas.
Flux ATEX drum pumps are manufactured primarily from 316 stainless steel, which is a conductive material. The pumps also have conductive PTFE bearings and impellers that comply with ATEX pump requirements.
Flux ATEX centrifugal pumps include our F 424, F 430 and F 425 series models. These are designed for handling low viscosity fluids up to a maximum viscosity of 1,200 mPas. The F 430 S FOOD model is approved for food and beverage applications, carrying Ex, FDA CFR 21 and EC 1935 / 2004 sanitary certification. This pump is perfect for transferring ethanol and finished alcoholic beverages in distillery applications.
Flux F 460 Ex and FBM 4000 Ex electric motors and F 416 Ex compressed air powered motors have the appropriate ATEX certification. There is a common misconception that compressed air motors are safer than electric motors when used in a Zoned area. However, this is not the case. Each product carries a specific ATEX type-code and they are equally safe to use. However, careful consideration must be given to power supply connection location, specifically, whether Ex-approved plug sockets are required.
Flux ATEX impeller pumps cost from approximately £1,500, increasing to over £4,000 for progressive cavity pumps. Prices vary depending on factors, such as pump size and type, motor power and materials of construction. Additionally, whether options such as discharge hose, swaged hose connections, earth cables and flowmeters are specified.
Flux produces RFM series air-operated ATEX diaphragm pumps, constructed from conductive PTFE and polypropylene materials. These pumps are available with a choice of elastomers for handling specific fluids.
