ATEX-classified zones, connected sensors, predictive maintenance… These concepts are becoming increasingly common in the industrial world. Yet, when it comes to implementing a project in the field, many technical and regulatory questions arise. As a maintenance manager, how can you ensure you’re choosing the right sensors? What criteria should be considered? What tangible benefits can you expect from an IoT solution in these high-risk environments?
This practical guide will help you sort through the options, ask the right questions, and better manage your connected maintenance projects in ATEX zones.
ATEX zones: a strict regulatory framework
ATEX zones (short for ATmosphères EXplosibles) refer to industrial environments where a mixture of gases, vapors, or dust may pose an explosion risk. These zones are classified according to the level of exposure to danger (Zone 0, 1, or 2 for gases, Zone 20, 21, or 22 for dust).
Equipment installed in these zones must be ATEX-certified according to strict European standards (e.g., EN 60079). This applies to all electrical and electronic devices, including connected sensors used for remote monitoring.
Why integrate IoT sensors in ATEX zones?
The main objective is to reduce human risk and optimize maintenance operations. By installing ATEX-certified connected sensors, it becomes possible to: :
– Remotely monitor critical parameters (level, temperature, pressure, flow, etc.)
– Detect early signs of malfunction or drift
– Schedule targeted interventions at the right time
– Reduce trips into hazardous areas
– Minimize unplanned downtime
Connected sensors for ATEX zones: key Criteria
For a connected sensor to be reliable and compliant with ATEX requirements, several factors must be considered:
– Official TEX certification and traceability of components
– Made with materials resistant to extreme conditions (heat, humidity, dust)
– Sealing quality, shielding robusteness, and safe spacing between electronic components
– Power autonomy (low energy consumption / long-life battery)
– Compatibility with industrial communication protocols (LoRaWAN, Modbus, etc.)
– A trustworthy sensor provider should be able to supply all necessary technical documentation and certifications.
What types of measurements can be automated?
Connected sensors can be used for a wide range of applications, even in constrained environments, such as:
– Level measurement in LPG or fuel oil tanks
– Remote monitoring of steam traps
– Remote reading of gas/water meters
– Monitoring of temperature, humidity, pressure
– Vibration analysis
These data can be automatically fed into a supervision platform or integrated with an existing CMMS (Computerized Maintenance Management System)
What should you plan for in an ATEX sensor project?
A connected maintenance project involving sensors in an ATEX zone requires careful planning. From a maintenance perspective, it’s important to anticipate:
– Network architecture and sizing (radio range, obstacles)
– Ease of installation without heavy rewiring
– Access to data (visualization, alerts, history)
– Maintenance management of the sensors themselves
– Training teams to use the newly available data.
Successful deployment depends as much on choosing the right sensors as on securing buy-in from field teams. You should also address data and information system security aspects, in collaboration with the company’s IT teams, including:
– Rules for data access and organization (also known as data governance)
– Compliance with, or even strengthening of, existing data sovereignty and cybersecurity policies
Conclusion
ATEX-certified connected sensors have become a practical and reliable solution for improving safety, securing installations, and anticipating failures in high-risk explosive industrial environments. As a maintenance manager, having the right technical and regulatory insights allows you to manage such projects with confidence — and generate real operational ROI.
Considering a connected sensor project in an ATEX environment? Contact our team for technical support and to explore our range of ready-to-use certified sensors.