XES was appointed by QUATT B.V. to conduct a hazardous area compliance review for their R290 air-to-water heat pump system. The assessment focused on determining whether the design and installation of the system necessitate formal hazardous area classification under the DSEAR Regulations (UK) and NPR 7910-1 (Netherlands), in alignment with ATEX Directive 1999/92/EC and associated product safety standards.
Assessing DSEAR and ATEX Compliance for R290 Heat Pump Systems in The Netherlands
Overview
XES carried out a hazardous area classification (HAC) and ignition risk review for the QUATT R290 system, referencing DSEAR and the relevant European and international standards governing hydrocarbon based refrigerants.
The primary standards referenced were:
IEC 60335-2-40: Safety of electrical heat pumps
EN 378-2 / ISO 5149: Safety and environmental requirements for refrigerating systems
IEC 60079-10-1: Area classification methodology
NPR 7910-1: Dutch implementation of ATEX risk management principles
The unit uses R290 (propane), a Class A3 highly flammable refrigerant, with a 480g charge per unit. The assessment was to verify if the system design prevented the need for formal zoning by demonstrating adequate control of release risk and ignition sources.
The unit uses R290 (propane), a Class A3 highly flammable refrigerant, with a 480g charge per unit. The assessment was to verify if the system design prevented the need for formal zoning by demonstrating adequate control of release risk and ignition sources.
Understanding the challenge
The central challenge was to evaluate whether the declared refrigerant charge, system sealing and outdoor installation conditions were sufficient to mitigate the formation of an explosive atmosphere, allowing for exemption from hazardous area zoning.
This required evaluating:
Our Approach and Implementation
We reviewed manufacturer supplied data, test certificates and safety documentation for the system and assessed refrigerant containment strategy (brazed joints, sealed circuit, leak testing).
Verified protection features including: Overpressure cut-off, Gas separator and backflow prevention IPX4 weather protection.
We then applied IEC 60079-10-1 to evaluate potential hazardous zone formation, and also:
Compared design against applicable standards: EN 378-2, ISO 5149, IEC 60335-2-40.
Analysed installation parameters including minimum clearance and natural ventilation adequacy.
Assessed NPR 7910-1 criteria to determine whether the design justified exemption from zoning
Primary Objectives
Impact and Outcomes Delivered
XES confirmed the R290 heat pump system hazardous area classification outcome and provided operational safety provisions.
The final report provided the client with:
Frequently Asked Questions
Questions about DSEAR, ATEX, Process Safety, Fire Safety, engineering management or explosion safety compliance?
These FAQs cover the most common queries we receive – But if you need tailored advice, get in touch.
I already have a DSEAR Risk Assessment – what are the benefits of having a Technical Authority?
While a DSEAR Risk Assessment satisfies legal obligations, appointing a Technical Authority adds a crucial layer of defensibility and accountability. A Technical Authority ensures that all zoning, ignition risk decisions, control measures and documentation are technically robust, traceable and aligned with legislation. This provides clear ownership of decisions, supports consistency and strengthens your position in the event of enforcement action, audits, or incident investigations demonstrating that your approach is not just compliant, but independently validated and defensible.
What’s the difference between ATEX and UKCA (UKEX)?
ATEX is the EU directive covering equipment and protective systems in explosive atmospheres. In the UK, this has been replaced by the UKCA (UKEX) marking. Both require conformity assessment and documentation, but UKCA is regulated under UK law. The UK government has extended recognition of CE marking for placing ATEX products on the market in Great Britain indefinitely beyond December 2024. The decision to apply UKEX on products being placed on the market in Great Britain is now the manufacturer’s choice.
This means that as 2025, manufacturers can choose to use either:
CE marking under ATEX (EU regulations), or UKCA marking under UKEX (UK regulations).
Both are currently accepted in the UK market, though the technical requirements of UKEX mirror those of ATEX.
What is the value of structured process safety studies?
Structured process safety studies provide a systematic, engineering led approach to hazard identification and risk reduction across all phases of the plant lifecycle. Techniques such as HAZID, HAZOP, LOPA, and SIL determination enable traceable evaluation of initiating events, safeguard effectiveness, and tolerable risk criteria in line with ALARP principles.
These studies form the technical backbone of a site’s safety case or explosion protection strategy ensuring that risk reduction measures are not only applied, but justified. Conducted at defined project gateways, they support functional safety compliance (e.g. IEC 61511), facilitate design stage intervention and create a defensible basis for operational and maintenance decisions under DSEAR, COMAH, and wider regulatory frameworks.
What role do FRA and FERA play in managing fire and explosion risk?
A Fire Risk Assessment (FRA) evaluates fire hazards, means of escape, detection and protection systems to ensure compliance with the Regulatory Reform (Fire Safety) Order 2005. It is a legal requirement for most premises and forms the foundation of a site’s fire safety management strategy.
A Fire and Explosion Risk Assessment (FERA) goes further, incorporating both fire and explosion scenarios such as flash fires, pool fires, jet fires, and vapour cloud explosions (VCE) often in higher risk or COMAH regulated environments. FERA integrates consequence modelling, escalation risk and cross-discipline interfaces with DSEAR, ATEX, and process safety.
At XES, we deliver both FRA and FERA ensuring that fire and explosion risks are not only identified but understood, mitigated and fully defensible.
Our Projects
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Assessing DSEAR and ATEX Compliance for R290 Heat Pump Systems in The Netherlands
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