Our client at Saltend Chemicals Park engaged XES to conduct a detailed ignition hazard assessment (IHA) and compliance review for four Palfinger pedestal cranes originally designed for Zone 2 operation. The cranes were installed in a Zone 1 hazardous area, prompting the need for an evaluation under ATEX Directive 2014/34/EU and associated functional safety requirements.
Helping Saltend Chemicals Park with ATEX Zone 1 compliance of a pedestal crane
Overview
XES undertook a structured assessment aligned with BS EN ISO 80079-36 and 80079-37 to determine the suitability of the cranes for continued use in Zone 1.
As part of the review, BS EN 13852-1:2013 and BS EN 13852-3:2021 were adopted to assess equipment specific hazards, technical risk reduction measures and conformity with the essential health and safety requirements (EHSRs) of the Machinery Directive 2006/42/EC particularly those related to fire and explosion (EHSRs 1.5.6 and 1.5.7).
The crane specific standards are designated as Type C standards under EN ISO 12100:2010 and provide detailed guidance for offshore crane safety, including lifting mechanisms, load handling and hazardous environment design considerations.
The crane specific standards are designated as Type C standards under EN ISO 12100:2010 and provide detailed guidance for offshore crane safety, including lifting mechanisms, load handling and hazardous environment design considerations.
Understanding The Challenge
To validate whether Zone 2 certified mechanical equipment could be considered suitable for Zone 1 service without modification or recertification.
This required a forensic review of all potential ignition sources under both normal and fault conditions, and verification of safety measures implemented during original design and installation.
Furthermore, the assessment involved evaluating safety-related control functions against ISO 13849-1, including determination of the required Performance Level (PLr), verification of functional integrity, and adequacy of safety function response.
Our Approach and Implementation
Our assessment began with a site inspection and full asset verification at Saltend Chemicals Park, allowing our team to gain a clear understanding of the crane installations, operating context and associated ignition risks.
A structured ignition hazard assessment (IHA) was completed in accordance with BS EN ISO 80079-36 and 80079-37, addressing typical mechanical ignition sources including frictional heat, hot surfaces, and electrostatic discharge.
We then reviewed the safety-related control functions in line with ISO 13849-1, establishing required Performance Levels (PLr) and verifying whether the implemented control measures met the necessary safety function performance criteria. This included assessing the functional integrity of systems responsible for preventing hazardous conditions during crane operation.
To support Machinery Directive compliance, we adopted BS EN 13852-1:2013 and BS EN 13852-3:2021, both recognised as Type C standards under EN ISO 12100:2010, as part of our wider review. These standards provided a structured framework for evaluating crane specific hazards and technical risk reduction measures. Conformity with the essential health and safety requirements (EHSRs) of the Machinery Directive was verified through detailed cross referencing with the client’s technical file, inspection reports and manufacturer documentation.
Primary Objectives
Impact and Outcomes Delivered
XES provided a comprehensive ATEX and functional safety assessment for the crane systems, providing detailed measures required for their continued use in a Zone 1 hazardous area.
The client was supplied with a technically robust report which defined necessary measures required for conformity to applicable directives and standards. Verification of safety functions and PLr compliance under ISO 13849-1 reinforced operational assurance.
Our input also supported broader sitewide DSEAR compliance and contributed to the client’s hazardous area integrity programme.
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
17/04/25
Assessing DSEAR and ATEX Compliance for R290 Heat Pump Systems in The Netherlands
20/12/24
Delivering a full Explosion Protection Document (EPD) and DSEAR compliance review for Bakels
Partner with XES to protect your people, assets and reputation