EX Inspections Explained
Legal Duties, Methods & Common Pitfalls (2025)
TL;DR
EX inspections verify that every junction box, light or motor installed in Zones 0-2 / 20-22 still meets its ATEX / IECEx protection rating.
Initial → periodic → sample inspections catch corrosion, loose glands, non-Ex replacements and paperwork gaps—the very faults that ignite 30 % of industrial fires EU eMARS data.
1. Why EX inspections exist
- Legal mandate – ATEX 153 (1999/92/EC) §4 and IEC 60079-17 demand periodic verification.
- Risk control – 73 % of Zone-1 incidents involve degraded equipment seals or loose cable entries (DEKRA Process Safety 2024).
- Insurance & audit – underwriters ask for up-to-date Ex Register with inspection dates and findings.
2. Inspection types & frequency (EN 60079-17)
Table 1 Inspection regime| Type | Scope | Performed by | Typical interval* |
|---|
| Initial (Detailed) | All equipment & wiring before energising | Comp Ex 01 (or equivalent) inspector | Once, new install / major revamp |
| Periodic
Visual / Close / Detailed | 100 % items at defined frequency | Competent Ex technician | 1–3 yr (Zone 0/20) • 3–6 yr (Zone 1/21) • 5 yr+ (Zone 2/22) |
| Sample | Random % of low-risk items | Same as periodic | As risk assessment dictates |
*Intervals may be shortened by insurer or site-specific risk.
3. Who is qualified?
- IECEx CoPC units 001-008 (or CompEx 01-10) prove competence.
- “Responsible person” must have 3 + yrs experience + formal ATEX/IECEx training.
- Assistants may carry out Visual tasks under supervision.
4. What inspectors need on site
- Most-recent Zone drawings & Ex Register.
- Certificate dossier (ATEX, IECEx, UKEX as applicable).
- Low-energy IS flashlight, feeler gauges, IP54 camera.
- Calibrated torque driver & gap measurement tools.
- Optional → NFC / QR scanner linked to digital register.
5. Common findings (2022-24 EU refinery survey)
| Fault | % of units affected | Root cause |
|---|
| Loose cable gland | 24 % | Vibration + poor torque control |
| Missing Ex label | 18 % | Paint overspray / maintenance swap |
| Corroded flamepath bolt | 15 % | Coastal atmosphere – no grease |
| Non-Ex junction box in Zone 2 | 11 % | Spares shortage, fast fix |
6. Main challenges for asset owners
- Data sprawl – 5k + items in spreadsheets with no revision control.
- Offline work – inspectors lose Wi-Fi inside tank bunds.
- Certificate traceability – PDFs sit in email archives, not linked to tags.
- Photo evidence – gigabytes of JPGs unlinked to findings.
- Audit time sink – compiling a single Ex report can take weeks.
7. Digital solution spotlight
EXREG solves the above by:
- One cloud Ex Register with bulk import & API.
- Offline-ready Android app – QR/NFC scan, photo attach, auto time-stamp.
- Instant EN 60079-17 PDF report generator.
- Power BI / Grafana feed for KPI dashboards.
8. Further reading
9. Conclusion
EX inspections are the routine medical check-ups your plant can’t skip.
A structured, digital workflow shrinks cost and closes gaps before auditors—or explosions—find them.
Level-up your next inspection round →
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