Product compliance with ATEX/IECEx

[Alex]

Hello all, I am trying to navigate the requirements regarding the design, manufacture and type testing of products for use in potentially explosive atmospheres.
We are at the early stages of the design cycle for a new product and I am trying to 'design for Ex' early on, so as to avoid expensive modifications closer to production.
The product is an industrial meter, the sort of 'canisters' or 'transmitters' you see installed on pipes in industrial plants. To use ATEX terms, we are likely aiming for equipment group II, atex category 2 for operation in Zone 1, gas subgroup IIB. The product will ultimately go on the European, North America and Middle East market.

I guess my overarching question to those of you who might have gone through this before how to best go about this whole process. I could, for example, identify all applicable Ex standards and laws in said territories and dive into those. I could engage a notified body for design steering, but they (I have tried DNV-GL, there are many more) have stated conflict of interest as they are doing the certifications. I have not been able to find a small outfit type consultant to help navigate the journey, although there are larger companies that could potentially help, if they are willing to engage with our micro company. Is there any advice you can give me on how to approach this?

Similarly, I have identified Ex certified enclosures, for example like these, which seem to carry the required certifications for the target environment. If we were to use such an enclosure, what does that mean for the design of the optics and electronics inside the unit and final product certification? Another important question is around certification required for prototype testing in field trials; do these have to be fully certified like the final product or are they partially exempt?

Any pointers would be extremely helpful; perhaps you have worked with some companies/contractors/consultants in the past that you can share?

Thanks
Alex

[sicco]

https://www.exalondelft.nl/corporate/overview/

[floobydust]

I would suggest getting your requirements nailed down - what countries and markets will you be selling the product into?
What method of protection are you going to use? What Zones, Gas Groups etc. ?
If you aim too high, it can sink a small company due to the time and costs involved. This has to be well defined up front - how much are you willing to spend in regulatory?

Ex adds cost to the enclosure and fittings but is much easier for design and certification. With IS the bar is much higher, which means more design mistakes/rework and time in certification. It will take months longer, which is expensive and there can even be a deal-breaker such that the design can never achieve IS due to the power involved or capacitance etc. If you have no experience with IS then I would shy away from going down that road as a start unless your employer wants to build up that engineering ability.

ATEX I found was very difficult to find manufacturers (pcb stuffing) that are certified. The record keeping is extreme, example- a faulty capacitor lot can be traced down to the boards and products affected, in the event of safety issue or recall. I did work with ACL in Manchester, they have their own system for full traceability and a decent shop.

Field trials with something uncertified are dangerous of course, companies will not allow it as it invalidates their insurance. Nobody wants something that could go boom installed at  their site. What would you be testing anyhow, the hardware and firmware should be solid, tested in a non-hazardous location.

Other people here have ATEX designs experience and might chime in. I've stayed in IEC 60079 for designs in hazardous locations.
P.S. Stay away from SGS Baseefa, I've seen them approve unsafe products and they are clown approvers, just terrible.