-300x300.jpg&w=48&q=75){kind=small}
Author: Veress Árpád · Explosion-protection expertDAILY Ex - 7 NOVEMBER 2026
TODAY'S FOCUS: Ageing Ex equipment does not automatically require replacement-but continued operation requires technical evidence. A new Malaysian initiative addressing ageing explosion-protected equipment, a fatal industrial maintenance accident in Türkiye, and renewed questions about the technical integrity of older Ex installations lead today's edition. Today's Operational Ex case examines a frequently overlooked modification: increasing production capacity without reviewing the ventilation system. For Heads of Operations: The objective is not to replace every old asset. It is to demonstrate that every asset remains suitable for its actual operating conditions.
⚡ DAILY Ex | 7 NOVEMBER 2026
Explosion Protection | Operational Ex | Global Watch
TODAY'S FOCUS: Ageing Ex equipment does not automatically require replacement-but continued operation requires technical evidence.
A new Malaysian initiative addressing ageing explosion-protected equipment, a fatal industrial maintenance accident in Türkiye, and renewed questions about the technical integrity of older Ex installations lead today's edition.
Today's Operational Ex case examines a frequently overlooked modification: increasing production capacity without reviewing the ventilation system.
For Heads of Operations: The objective is not to replace every old asset. It is to demonstrate that every asset remains suitable for its actual operating conditions.
🔴 1. TÜRKİYE | Fatal explosion during industrial tyre inflation
NEW INCIDENT - 6 November 2026
An industrial accident at a steelworks in Aliağa, İzmir, killed one worker and injured another.
According to local reporting, the explosion occurred while workers were inflating a heavy-equipment tyre.
The 30-year-old worker died after being transported to hospital. Authorities opened an investigation.
The precise failure mechanism has not yet been established.
Important distinction: This was a reported tyre-inflation explosion, not a confirmed explosive-atmosphere incident.
Why it matters operationally: Maintenance activities can release significant stored mechanical energy even where no flammable atmosphere exists.
Management action: Verify tyre-inflation procedures, suitable restraining equipment, exclusion zones and maintenance competence.
https://www.izmirgaste.com/izmir-aliaga-da-is-kazasi-lastik-patladi-1-isci-hayatini-kaybetti/3764/
⚙️ 2. MALAYSIA | Ageing Ex equipment: assessment before replacement
NEW INDUSTRY DEVELOPMENT - 6 November 2026
Malaysian industrial solutions provider ISEP (M) Sdn Bhd has highlighted the growing challenge of ageing explosion-protected electrical equipment across Southeast Asia.
The initiative addresses equipment exposed to humidity, corrosion and demanding operating conditions, particularly in refineries, petrochemical facilities and offshore installations.
The company advocates structured technical assessment before deciding whether older equipment must be replaced.
It references IEC 60079-17:2023 Annex C as part of this approach.
This is a manufacturer/service-provider initiative, not a newly introduced regulatory exemption.
Why it matters operationally: Missing documentation or ageing equipment does not automatically justify replacement, but neither does historical operation establish continued safety.
Management action: Establish a documented assessment route for ageing Ex equipment, including identification, condition, technical evidence and any applicable national regulatory requirements.
📘 3. IECEx | Repair competence and ageing equipment
CERTIFICATION AND STANDARDS PRACTICE
The IECEx publishes technical capability documents for certification bodies assessing Ex repair and service facilities.
Its IEC 60079-19:2025 Technical Capability Document, Edition 5.0, was published in April 2026.
The document addresses the competence of certification bodies to assess service facilities against their proposed scope of repair activities.
It does not constitute a blanket authorisation for every repair facility or every equipment repair.
Why it matters operationally: An ageing Ex motor may be technically repairable, but the repair route must be justified and documented.
The decision must consider the protection concept, available certification information, applicable technical requirements, repair limitations and competence.
Management action: Separate three decisions: continued operation, technical repairability and acceptance for return to service.
https://www.iecex.com/resources-and-news/tcds/
⚖️ 4. EU / IEC | When is replacement equipment a modification?
REGULATORY PRACTICE
Under Directive 1999/92/EC, employers must maintain an explosion-protection document reflecting the installation's actual risks and relevant changes.
ATEX Directive 2014/34/EU addresses qualifying equipment and protective systems placed on the market or put into service.
IEC 60079-14 provides installation requirements, while IEC 60079-17 addresses inspection and maintenance.
These obligations must be considered together.
Why it matters operationally: Replacing an ageing Ex motor with a newly certified motor does not automatically establish that the installation remains compliant.
Changes in power, speed, cooling, converter characteristics, cable entries or mechanical interfaces may require reassessment.
Management action: Treat replacement as an engineering verification activity, not simply a purchasing transaction.
🔬 5. GLOBAL | Explosion-proof enclosure demand and industrial automation
NEW MARKET RESEARCH — 6 November 2026
A newly published market analysis forecasts continued growth in explosion-protected enclosures through 2035.
The report identifies industrial automation, ageing infrastructure and hazardous-area electrical upgrades as important demand drivers.
Its projected growth figures are commercial forecasts, not independently verified certification or safety-performance data.
Why it matters operationally: More automation generally means more electrical equipment, interfaces and communication systems requiring appropriate hazardous-area engineering.
Engineering lesson: Ex d, Ex e, Ex i and Ex p are different protection concepts with different design, installation and maintenance requirements.
An enclosure described commercially as explosion-proof is not automatically suitable for every hazardous area.
📘 6. UK | A maintenance procedure created a major LPG release
HISTORICAL INCIDENT LEARNING - Enforcement May 2026
The UK Health and Safety Executive reported enforcement action following a propane release at the Braefoot Bay Marine Terminal.
During loading-arm operations, an unintended activation of a remote-control function caused an emergency-release coupling to disconnect before the system had been adequately cleared of propane.
Approximately 250–300 kg of liquid propane escaped under pressure.
Investigators found that the operating procedure conflicted with the loading-arm manufacturer's instructions.
Why it matters operationally: A protective device can create a hazardous situation when operating procedures and equipment functions are not correctly coordinated.
Historical lesson: Emergency-release systems, isolation functions and maintenance procedures must be assessed as a complete operating arrangement.
📅 7. UK | Hazards 36 approaches
UPCOMING EVENT - 17-19 November 2026
Hazards 36 will bring together process-safety specialists in Manchester.
Relevant topics include major-hazard management, protective barriers, operational risk and learning from industrial accidents.
Why it matters operationally: Engineering competence must be supported by management systems that ensure protective measures remain effective throughout the installation lifecycle.
▶️ OPERATIONAL Ex USE CASE
The production dryer receives a capacity increase. The ventilation system remains unchanged.
PRACTICAL | Illustrative scenario
A chemical-processing facility operates a solvent-based drying process.
The dryer has an established operating envelope, ventilation arrangement, hazardous-area classification and protective interlocks.
Production wants to increase throughput by 20%.
Engineering confirms that the drive motor and mechanical components can accommodate the additional load.
The production increase is approved.
But what happens to the solvent evaporation rate?
Higher throughput may increase solvent-vapour generation.
If the ventilation system remains unchanged, vapour concentrations may increase during normal operation or foreseeable abnormal conditions.
The original hazardous-area classification and ignition-prevention assumptions may no longer be valid.
The key question is not whether the fan is running.
It is whether the ventilation system provides the required protective performance under the revised operating conditions.
The review should consider solvent loading, evaporation rate, airflow distribution, lower explosive limit, ventilation reliability, detection, interlocks and shutdown functions.
Where concentration control is a credited protective measure, its effectiveness must be demonstrated for the revised operating envelope.
Required decision: Process Engineering must verify that the increased production capacity remains within the assessed and protected operating conditions.
Owner: Head of Operations, supported by Process Engineering, Mechanical Engineering and the Ex Responsible Person.
Required evidence: Updated process assessment, ventilation calculations or measurements, review of hazardous-area classification, verification of protective functions and Management of Change authorization.
STOP criterion: Do not operate at the increased capacity until the revised explosion-prevention arrangements have been verified.
Measure: 100% of production-capacity changes assessed for their effect on explosion protection before implementation.
▶️ TODAY'S Ex QUESTION
A solvent dryer increases throughput by 20%, while its ventilation airflow remains unchanged. What must be established before continued operation at the higher capacity?
A. The existing Ex motor certificate remains valid.
B. The fan operates at its original speed.
C. The revised vapour-generation rate remains adequately controlled under normal and foreseeable abnormal conditions.
D. The dryer temperature remains below the solvent's autoignition temperature.
Correct answer: C.
The original ventilation and explosion-prevention assumptions may no longer be valid after a capacity increase.
⚡ DAILY Ex | CLOSING THOUGHT
Today's developments connect two important aspects of industrial explosion protection.
Ageing equipment may remain suitable for continued service when supported by adequate technical evidence.
At the same time, relatively new equipment may become unsuitable when production conditions change beyond its original assessment.
Equipment age is not the decisive factor. The decisive factor is whether the equipment and protective arrangements remain suitable for the actual operating conditions.
For Heads of Operations, this requires a continuous connection between asset integrity, engineering assessment, inspection, maintenance and Management of Change.
The installation operating today must remain within the conditions for which its explosion protection has been demonstrated.
That is Operational Ex.