Our client engaged XES to produce a site-specific Explosion Protection Document and undertake a structured compliance review under the Dangerous Substances and Explosive Atmospheres Regulations (DSEAR). The project focused on assessing the handling, transfer and storage of flammable materials across manufacturing operations.
Delivering a full Explosion Protection Document (EPD) and DSEAR compliance review for Bakels
Overview
XES delivered a formalised Explosion Protection Document in accordance with ATEX 153 and DSEAR.
The project included a full Hazardous Area Classification (HAC) review and a qualitative ignition risk assessment aligned with operational practices and zoning outcomes.
The EPD incorporated equipment assessment, ventilation strategy review and zoning drawings tailored to the site layout and process flows.
A total of 12 primary hazardous zones were defined across production, warehousing and external IBC handling areas. Where applicable, non-electrical equipment was reviewed against BS EN ISO 80079-36, while electrical systems and temporary installations were benchmarked against the IEC 60079 series.
A total of 12 primary hazardous zones were defined across production, warehousing and external IBC handling areas. Where applicable, non-electrical equipment was reviewed against BS EN ISO 80079-36, while electrical systems and temporary installations were benchmarked against the IEC 60079 series.
Understanding the challenge
The client contracted XES to help safeguard their plant, processes and people against potentially explosive atmospheres, inline with DSEAR.
The site handles a broad range of flammable substances, including combustible powder additives. These are introduced via bulk containers, smaller packaging lines and integrated dosing systems. While some risk control measures were already in place, our client required a formal EPD to evidence compliance, support audit readiness and address process specific ignition hazards.
Complexity arose from the mix of legacy and modern plant assets, ventilation effectiveness and the presence of ATEX machinery operating across multiple rooms with changing occupancy and cleaning regimes. It was essential to assess both continuous and transient explosive atmospheres arising during operations such as tipping, decanting and CIP procedures.
Our Approach and Implementation
We started with a full site walkdown and asset verification to map flammable material pathways, process interfaces and potential points of release. Developing HAC with zoning extents determined by ventilation performance, release grades and process frequency.
We reviewed all potential ignition sources; mechanical, electrical, electrostatic, thermal etc and evaluated the adequacy of protective measures. The risk assessment was developed with engineering and operational inputs. Equipment installed within defined zones was assessed for ATEX conformity, including temporary tools, sensors and non-electrical rotating machinery.
The EPD was developed as a live document covering hazardous substance inventory, risk assessment outcomes, inspection protocols, zoning rationale and a DSEAR improvement action plan.
Primary Objectives
Impact and Outcomes Delivered
XES delivered a complete EPD tailored to the operational needs and hazard profile of the site. The document included detailed zoning maps, risk justification tables and a prioritised compliance improvement register, enabling the client to clearly demonstrate DSEAR and ATEX compliance.
The assessment provided assurance to internal stakeholders and external regulators, ensuring that hazardous area risks were formally documented, proportionately controlled, and embedded into the site’s ongoing safety management system. Our engagement strengthened the site’s risk governance and helped set a consistent standard for future modifications and installations.
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.
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Delivering a full Explosion Protection Document (EPD) and DSEAR compliance review for Bakels
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