Industrial machine conversion for ATEX zones

CentrExpert, Europe's leader in compliance, intervenes in the transformation of industrial machinery in many high-risk sectors such as petrochemicals, pharmaceuticals, and the agri-food industry. 

What is ATEX transformation?

This is the technical modification of a standard machine so that it can operate safely in an Explosive Atmosphere. It is a complex process that aims to identify and eliminate all potential sources of ignition: mechanical sparks, static electricity, hot surfaces, or electric arcs.

Conversion or transformation: what's the difference?

On the one hand, ATEX transformation evokes the structural aspect and heavy engineering. This involves transforming the chassis or the cooling circuit, for example.
On the other hand, ATEX conversion marks the transition from a “standard” state to a “protected” state.
At CentrExpert, we talk of global transformation because our expertise goes far beyond adding components. Indeed, we rethink the machine's security architecture to ensure explosion-proof protection without ever compromising its initial performance.

Why convert a machine for explosive atmospheres?

Modifying an existing piece of equipment or purchasing a standard machine for conversion offers three major advantages:

  1. The cost: retrofitting is often more competitive than buying an original ATEX machine. In fact, they are rare on the market and often very expensive.
  2. Ergonomics: your operators can maintain their habits on models they already know (forklifts, pumps, or interfaces).
  3. Availability: ATEX factory machine manufacturing lead times can be very long. Ultimately, the conversation allows for a faster commissioning.
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Industrial machines modified for ATEX zones

Our design office has multi-brand and multi-equipment experience. This allows us to work on high-power systems. 

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Handing trolleys converted

Our teams transform forklifts, pallet trucks, and stackers, whether they are electric or internal combustion. We are the partner of the largest manufacturers. In this capacity, we adapt batteries, motors, and braking systems for complete safety in zones 1, 2, 21, or 22.

ATEX Generator Sets

We also convert high-power generator sets (up to 1,200 KW) for your energy needs on sensitive sites or offshore platforms. This includes exhaust gas cooling and alternator safety.

Motor-pump groups and very high pressure

We convert pumping units up to 3,000 bar. These units, critical for industrial cleaning or fluid transfer, receive explosion-proof protection. We transform the hydraulic and motor components with absolute rigor.

Internal combustion engines

We are specialists in diesel engine conversion. Our teams install flame arrestors, air shut-off valves, and heat exchangers to keep surface temperatures below the auto-ignition point of the present gases.

But also: housings for industrial cameras

At CentrExpert, we design specialized enclosures that offer explosion-proof protection for your optical monitoring and inspection systems. These housings secure your control processes as close as possible to high-risk areas.

Our methodology

The machine's transformation follows a strict protocol. This way, we guarantee flawless certification at the end of the line.

ATEX Risk Analysis

This is the crucial step. First, we list all ignition sources of the original machine: friction, electricity, heat, sparks. This analysis defines the required Equipment Protection Level (EPL) according to the target zone.

Conceptualizing Transformation

Our design office draws up the modification plans. Then, we choose between explosion-proof enclosure protection, increased safety, or immersion. All this while ensuring operational performance is maintained.

ATEX Specific Component Design

We manufacture the parts that don't exist. At CentrExpert, we integrate our own innovations, such as our autonomous gas detection systems. This is to enhance the active safety of the equipment.

Implementation, testing, and certification

Assembly is always carried out in our workshops by certified technician engineers. Each machine undergoes pressure, temperature, and leak testing before being approved by a notified body if necessary.

Delivery and full ATEX documentation

Since transformed equipment is nothing without documentation, we deliver a complete technical file: certificate of conformity, specific instruction manual, electrical diagram, and maintenance logbook.

What are the ATEX standards and directives?

ATEX certification must comply with precise standards to be legal. In Europe, this is the harmonized standard EN ISO 800079-36 and 37, which governs non-electrical equipment in explosive atmospheres. For electrical components, the EN 60079 series standards apply.

Discover ATEX standards

Questions
frequent

What is the difference between passive and active conversion?

Passive conversion relies on physical and mechanical barriers (enclosures, firewalls) that physically prevent an explosion or its propagation. Active conversion uses monitoring systems (gas detectors, temperature sensors) that automatically cut off the machine's power as soon as a danger threshold is detected.

We equip all hazardous areas: Zones 1 and 2 (Gas) as well as Zones 21 and 22 (Dust). For Zone 0 or 20, where the risk is permanent, we generally favor the design of specific custom-built machines.

By default, our transformers are ATEX certified for the European market. However, upon request, we can perform conversions that meet IECEx standards for international use, or specific standards (NEC, Inmetro, etc.) depending on the country of destination for the equipment.