What should you demand from a particle analysis system when working with compressors, pumps, or gearboxes in explosive environments?

In industrial environments classified as ATEX Zone 2 or Class I, Division 2 (Groups C-D, T4), any mechanical failure not only jeopardizes operations—it can also pose a real safety risk to the plant. That’s why predictive maintenance is no longer optional, especially when it comes to critical rotating equipment like compressors, pumps, or lubricated gearboxes.

One of the most effective technologies for anticipating failures in this type of machinery is particle analysis in the lubricant. But not all systems are created equal, and in explosive environments, the demands are higher.

Why Analyze Particles Instead of Just Tracking Hours or Doing Lab-Based Oil Analysis?

Because the metallic particles generated by rotating equipment are the first signs of failure. Their shape, size, and behavior in the fluid reveal whether it’s a case of:

• Normal wear vs. early-stage failure due to fatigue or abrasion
• External contamination vs. internal alignment or lubrication issues
• Failures that can evolve in hours, not weeks

And in an ATEX zone, waiting for the next lab analysis might be too late.

Atten[2] can help you to monitor your critical applications in explosive environments with our OilWear EX

7 Requirements a Particle Analysis System Must Meet in Explosive Environments

Here are the minimum criteria you should demand if you’re considering an online monitoring solution:

1. ATEX / IECEx / UL Certification for Zone 2 / Class I, Div. 2

Encapsulated electronics are not enough—the system must be officially certified to operate in explosive atmospheres, complying with the autoignition temperature of the present gas group and class.

🔎 Example: T4 indicates a maximum surface temperature of 135 ºC, common in plants with light hydrocarbon vapors.

2. Capability to Analyze Particle Shape

A basic particle counter (like those based on ISO 4406) is not sufficient. The system must be able to analyze particle shape, which helps identify the failure mode:

• Frictional wear
• Fatigue spalling
• Impact or cavitation

📈 This turns the sensor into a diagnostic tool—not just an alert system.

3. Discrimination Between Bubbles and Actual Particles

Equipment in classified zones often operates under high pressure, temperature, or transient conditions that generate foam or aeration in the oil.

➡ A good sensor must distinguish air bubbles from metallic particles to avoid false alarms that could trigger unnecessary shutdowns.

4. Detection of Dissolved or Free Water

Water ingress is a major threat to lubricated systems in ATEX zones. The system must detect both free and dissolved moisture, as water degrades oil and accelerates mechanical failure.

💧 Early water detection prevents corrosion, micro-cavitation, and loss of the lubricating film.

5. Continuous (24/7) Monitoring Without Human Intervention

The minimum requirement is that the sensor operates online, without manual sampling, and transmits real-time data. This enables action before failure progresses.

⏱ The goal is not just fast reaction—but early anticipation.

6. Integration with Remote Monitoring Platforms

The system must offer connectivity (Modbus, OPC UA, etc.) or software that allows viewing all connected equipment from a single interface, ideally with customizable alarms and event traceability.

📊 This facilitates decision-making at the plant or multi-plant level.

7. Proven Track Record in Real Applications

Promising technology isn’t enough—it must have real success stories in compressors, pumps, or gearboxes, ideally in ATEX-risk sectors like refineries, chemical plants, or automotive industries.

✅ For example, at an automotive plant with 24/7 compressors, oil life was extended 4x and a critical shutdown was prevented thanks to continuous monitoring of particles and water.

The oil is speaking to you. The question is: Are you listening?

In ATEX environments, it’s not just about detecting particles—it’s about interpreting what they reveal about the health of your critical assets. A system that meets the seven criteria above is not an expense: it’s an insurance policy for operational continuity and industrial safety.

If your compressors, pumps, or gearboxes operate in Zone 2 / Class I, Div. 2, don’t wait for failure.