The client operates multiple flammable processing facilities, handling flammable liquids and vapours. As part of their legal duties under the Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) 2002 they are required to ensure that all equipment installed within potentially hazardous areas remains safe for continued use.
Previous inspections had been completed intermittently, and documentation was inconsistent across different plant areas. The client required a structured, compliant Ex inspection programme to:
The primary challenge affecting the client’s compliance stemmed from the harsh environmental conditions at the coastal location, including exposure to salty air, high temperatures, and direct sunlight. These factors contributed to the corrosion of Ex-rated equipment, while prolonged UV exposure caused the Ex-nameplates to fade.
To address these issues, we recommended the use of more durable materials for glands and fittings, such as stainless steel, to minimise corrosion and extend service life. Additionally, we advised implementing protective measures to shield the nameplates from direct sunlight, ensuring their legibility and maintaining compliance over time.
The client specified the requirement for Close and Visual Inspection, although detailed inspection would be required at a future date.
Ex Inspections were completed for the following areas:
The inspection scope included:
Inspections were carried out in accordance with:
All findings were categorised as follows:
This allowed the client to prioritise resources and manage risk effectively.
The inspection programme across all the sites identified:
The Ex-inspection programme provided the client with confidence that their hazardous areas were being managed effectively and in line with current legislation and standards. By identifying defects early and prioritising corrective actions, the site can significantly reduce safety risks while improving long-term compliance and asset integrity.
The structured approach also enabled the client to move away from reactive maintenance towards a planned, risk-based Ex maintenance strategy.
