Explosion-proof electric actuators are designed for safe operation in hazardous environments, including oil and gas facilities, petrochemical plants, gas distribution stations, mines, and other areas where combustible gases or dust may be present.
The key design feature is a protective enclosure that prevents potential ignition sources, such as sparks, electric arcs, and hot surfaces, from igniting the surrounding explosive atmosphere. The safe selection and operation of an explosion-proof actuator depend on three key factors:
- Safety – prevention of ignition of the surrounding explosive atmosphere by the electric actuator.
- Certification – ocumented compliance with applicable ATEX, IECEx, and Ukrainian technical regulation requirements.
- Operating environment – compliance of the actuator marking with the hazardous zone classification, gas group, and temperature class.
We offer ATEX- and IECEx-certified electric actuators from the Austrian manufacturer Schiebel, supplied with a complete set of certificates for the Ukrainian market.
What Is an Explosion-Proof Electric Actuator?
An explosion-proof electric actuator is an electromechanical device used to control pipeline valves. Its design prevents potential ignition sources within the actuator from igniting the surrounding explosive atmosphere.
Such an actuator operates in areas where a combustible mixture of gas or dust and air may form. Even if an internal spark, excessive temperature, or electrical fault occurs, the actuator is designed to prevent ignition of the surrounding explosive atmosphere. This is achieved through certified protection methods, specialised enclosure designs, and other explosion-protection measures.
The most common explosion protection methods include:
- Ex d (flameproof enclosure) – the enclosure withstands the pressure of an internal explosion and prevents the explosion from propagating into the surrounding atmosphere.
- Ex e (increased safety) – the design prevents sparks, electric arcs, and dangerous overheating during normal operation.
- Ex de – a combined protection concept in which the main electrical enclosure is protected by Ex d and the terminal compartment by Ex e.
- Ex t – protection by enclosure against the ignition of combustible dust atmospheres.
Example of marking:
II 2G Ex db IIB T4 Gb
- II – equipment for surface industries;
- 2G – Category 2 equipment for gas atmospheres;
- Ex db – flameproof enclosure;
- IIB – gas group, including ethylene;
- T4 – maximum surface temperature of 135 °C;
- Gb – equipment protection level.
Where Are Explosion-Proof Electric Actuators Used?
Explosion-proof actuators are used wherever an explosive atmosphere may form.
- Oil and gas industry. Main gas and oil pipelines, compressor stations, gas distribution stations, and oil and gas production, processing, storage, and transportation facilities.
- Petrochemical and chemical industries. Facilities handling combustible gases, solvent vapours, and flammable liquids.
- Gas distribution systems. Gas distribution stations, pressure-reduction and metering units, and industrial boiler facilities.
- Mining industry. Mines with methane emissions and other underground workings.
- Grain and food industries. Grain elevators, feed mills, and flour mills with combustible dust explosion hazards.
- Power Generation and Nuclear Facilities. Hydrogen systems, individual process circuits, and other specialised facilities.
- Biogas facilities. Anaerobic digesters, bioreactors, and wastewater treatment plants.
Each industry has its own requirements for hazardous zone classification, gas group, temperature class, and additional applicable standards.
Classification of Hazardous Areas
Before selecting an electric actuator, the hazardous area classification for the installation location must be determined. Classification is carried out in accordance with IEC 60079-10 and DSTU EN 60079-10.
Gas Zones
| Zone | Description | Equipment Protection Level (EPL) |
|---|---|---|
| Zone 0 | An explosive atmosphere is present continuously or for long periods | Ga |
| Zone 1 | n explosive atmosphere is likely to occur occasionally during normal operation | Gb |
| Zone 2 | An explosive atmosphere is not likely to occur during normal operation and, if it does occur, will persist for only a short period | Gc |
Dust Zones
| Zone | Description | Equipment Protection Level (EPL) |
|---|---|---|
| Zone 20 | A cloud of combustible dust is present continuously | Da |
| Zone 21 | An explosive atmosphere in the form of a cloud of combustible dust is likely to occur occasionally during normal operation | Db |
| Zone 22 | A combustible dust atmosphere is unlikely to occur and, if it does, exists only briefly | Dc |
Gas Groups
- IIA – propane, methane, and petrol vapours.
- IIB – ethylene, coke oven gas, ethylene oxide.
- IIC – hydrogen and acetylene.
An electric actuator certified for IIC may also be used in IIB and IIA environments, but not the other way around.
Temperature Classes
- T1 – up to 450 °C
- T2 – up to 300 °C
- T3 – up to 200 °C
- T4 – up to 135 °C
- T5 – up to 100 °C
- T6 – up to 85 °C
Certification and Standards: ATEX, IECEx, and Ukrainian Requirements
Using equipment in a hazardous environment without the appropriate certification is a violation of safety requirements.
ATEX
EU Directive 2014/34/EU regulates equipment and protective systems intended for use in potentially explosive atmospheres. Certified electric actuators carry CE and Ex markings and are supplied with an EU Declaration of Conformity.
IECEx
IECEx is an international certification system based on the IEC 60079 series of standards and is used in more than 30 countries worldwide.
Ukrainian Technical Regulation
Resolution of the Cabinet of Ministers of Ukraine No. 1055 dated 28 December 2016 is harmonised with the requirements of the ATEX Directive. Compliant electric actuators may be placed on the Ukrainian market and used at industrial facilities in Ukraine.
Design Features of Explosion-Proof Electric Actuators
The design of an explosion-proof actuator differs significantly from that of a standard industrial actuator and includes a range of engineering solutions intended to prevent ignition of a hazardous atmosphere.
Certified Protective Enclosure
The flameproof enclosure, typically manufactured from cast aluminium alloy or stainless steel, is designed to withstand the pressure of an internal explosion and prevent flames from escaping. Flamepaths cool hot gases to a safe temperature.
Ignition Prevention Measures
- surface temperature limitation in accordance with classes T1–T6;
- absence of exposed sparking contacts;
- motor thermal protection using thermistors or thermal switches;
- torque overload protection;
- protective earthing of the enclosure.
Ex Cable Glands
Explosion-proof actuators use appropriately certified Ex cable glands with compound sealing or dedicated sealing systems.
Internal Heater
A built-in heating element prevents condensation from forming inside the enclosure and reduces the risk of short circuits.
Corrosion-Resistant Design
For operation in aggressive environments, epoxy or polyurethane coatings, stainless-steel fasteners, and specialised lubricants are used.
Manual Override
Explosion-proof electric actuators may be equipped with a manual handwheel that allows the valve to be operated in the event of a power failure.
How to Select an Explosion-Proof Electric Actuator
Explosion-proof electric actuators must be selected using a comprehensive engineering assessment. It is important to consider not only the parameters of the pipeline valve but also the exact hazardous area classification.
- Hazardous area classification. The installation location must be classified as Zone 0, 1, or 2 for gas atmospheres, or Zone 20, 21, or 22 for dust atmospheres. The classification is specified in the project documentation in accordance with DSTU EN 60079-10.
- Gas or dust group. Gas groups include IIA, IIB, and IIC, while dust groups include IIIA, IIIB, and IIIC. The actuator is selected according to the most hazardous substance that may be present at the facility.
- Temperature class. The required temperature class, from T1 to T6, is selected according to the ignition temperature of the potentially explosive substance.
- Type of explosion protection. Depending on the operating conditions, Ex d, Ex de, Ex e, Ex t, or combined protection methods may be used. Ex db or Ex db eb are commonly selected for Zones 1 and 2.
- Valve technical parameters. The required torque or thrust, number of turns or stem travel, operating time, and mounting interface must be considered. ISO 5210 is used for multi-turn actuators, while ISO 5211 applies to quarter-turn actuators.
- Certification. Equipment used in Ukraine must comply with the Technical Regulation approved by Resolution of the Cabinet of Ministers of Ukraine No. 1055. Compliance is confirmed by a Type Examination Certificate, a Notification of Conformity to Type Based on Product Quality Assurance, and a Declaration of Conformity.
- Environmental and climatic design. The ambient temperature range, humidity level, corrosive or marine atmosphere, and enclosure protection rating must be considered. IP66 is commonly used as the standard industrial rating, while IP68 is suitable for flood-prone chambers and severe operating conditions.
If the hazardous area classification has not yet been completed, or the facility includes several zones with different operating conditions, our engineers can review the available project data, determine the required equipment marking, and select a model suitable for all anticipated operating conditions.
Buy Explosion-Proof Electric Actuators in Ukraine
We offer ATEX- and IECEx-certified explosion-proof electric actuators for shut-off and control valves. Multi-turn, quarter-turn, and linear models are available with Ex d, Ex de, Ex e, and other protection concepts, depending on the application.
The product range is primarily based on equipment manufactured by the Austrian company Schiebel and available with a complete package of ATEX and IECEx documentation. These actuators are used at oil and gas, gas distribution, and power generation facilities throughout Ukraine.
What You Receive
- Technical selection. We select an electric actuator according to the hazardous zone, gas or dust group, temperature class, and valve parameters.
- Complete documentation package. Type Examination Certificate, Notification of Conformity to Type Based on Product Quality Assurance, Declaration of Conformity, operating manual, and other required documents.
- Engineering consultation. Assistance with explosion protection marking, installation, commissioning, and integration of the actuator into a process control system.
- Manufacturer’s warranty. The warranty period is specified in the documentation supplied with the selected model.
- Delivery across Ukraine. In-stock equipment is dispatched after payment confirmation, while made-to-order models are supplied according to the delivery schedule agreed in the contract.
The price of an explosion-proof electric actuator depends on the type of explosion protection, torque, control unit functionality, digital communication interfaces, environmental design, and additional options.
Frequently Asked Questions About Explosion-Proof Electric Actuators
What Is the Difference Between ATEX and IECEx?
ATEX refers to the EU regulatory framework for equipment intended for use in potentially explosive atmospheres, including Directive 2014/34/EU. IECEx is an international certification system based on the IEC 60079 series of standards.
The technical requirements of both systems are similar because they are based on the same IEC 60079 standards. However, ATEX and IECEx are administratively separate schemes with different certification procedures, documents, and conformity assessment systems.
Schiebel offers actuator models certified under both the ATEX and IECEx schemes. ATEX certification is used for supplies to the EU and Ukraine, while IECEx certification supports international projects and supplies to countries outside the European Union.
For facilities in Ukraine, compliance with Technical Regulation No. 1055 is mandatory and is confirmed by a Type Examination Certificate, a Notification of Conformity to Type Based on Product Quality Assurance, and a Declaration of Conformity.
How Is a Hazardous Area Classified?
Hazardous area classification is carried out during the facility design stage in accordance with DSTU EN 60079-10-1 for gas atmospheres and DSTU EN 60079-10-2 for dust atmospheres.
The following factors are considered:
- the type and quantity of the combustible substance;
- the frequency of formation of an explosive atmosphere;
- the effectiveness and availability of natural or mechanical ventilation;
- the geometry of the room or outdoor area;
- the ignition temperature of the substance;
- the relevant gas or dust group.
The result is a hazardous area classification drawing or plan showing Zones 0, 1, 2 or 20, 21, 22, together with the substance group and temperature class.
If the project documentation is unavailable or outdated, an accredited industrial safety organisation should be engaged. Incorrect area classification or equipment selection may create an accident risk and result in legal liability.
What Is the Service Life of an Explosion-Proof Electric Actuator?
Industrial electric actuators manufactured in Europe, including Schiebel models, may be designed for 10,000–25,000 full operating cycles and 20–25 years of service, provided they are correctly installed, commissioned, and maintained.
The actual service life depends on operating frequency, load, temperature, humidity, environmental aggressiveness, and compliance with the maintenance schedule.
For critical industrial facilities, a scheduled inspections should be carried out at the intervals specified by the manufacturer, applicable regulations, and the facility maintenance plan.
Can a Standard Actuator Be Upgraded to an Explosion-Proof Version?
No. Explosion-proof construction is not an optional add-on but a fundamentally different equipment design.
It requires a specific enclosure wall thickness, certified flamepaths, Ex cable glands, temperature monitoring, grounding, and other solutions that are tested as part of the complete actuator model.
Any unauthorised modification invalidates the factory certification. For operation in a hazardous area, an appropriately Ex-certified actuator with the required marking and documentation must be installed.
Are Schiebel Explosion-Proof Actuators Suitable for Ukrainian Oil and Gas Facilities?
Yes. Schiebel explosion-proof models are certified according to ATEX and IECEx and may be supplied with the documents required to confirm compliance with Technical Regulation No. 1055.
The equipment is supplied with technical documentation in Ukrainian or with an official translation. Schiebel electric actuators are used on oil and gas pipelines, gas distribution stations, and power generation facilities.
Do You Need an Explosion-Proof Electric Actuator for Your Facility?
Submit a request through the website or contact us by phone. Our engineer will review the specified hazardous area classification, gas or dust group, temperature class, valve parameters, and operating conditions.
After reviewing the information, you will receive a technically justified commercial proposal, including the recommended electric actuator model and a complete list of the required certification documents.
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