Because NO single stakeholder controls the whole chain.

Explosion protection only works when process control (primary), equipment design/selection (secondary), and consequence mitigation (tertiary) all align.

A risk gap occurs if even one stakeholder ignores one layer.

Stakeholder-by-Stakeholder Breakdown

Management / Site Owner

Must know all 3 because they:

• Approve design & modifications → Primary
• Approve procurement of correct equipment (EPL/category) → Secondary
• Approve explosion vents, suppression, isolation → Tertiary

❗If management doesn't understand all 3 → wrong investments → noncompliance → liability.

Engineering (Process, Mechanical, Electrical, Instrumentation)

They design and implement:

• Primary: ventilation, inerting, leak prevention
• Secondary: Ex equipment selection, zoning, ignition control
• Tertiary: containment, isolation, vent sizing

❗If engineers overlook one layer → design becomes unsafe and not compliant with IEC 60079-14 / 10-1 / 10-2.

Procurement / Purchasing

Often the forgotten but critical group.

They must understand:

• Primary: equipment must support correct process parameters
• Secondary: equipment must match zone, category, EPL, gas group, temperature class
• Tertiary: explosion-resistant or certified protective systems

❗Purchasing errors → the most common root cause of wrong category, non-Ex equipment, or unsafe substitutions.

Operations / Maintenance

They influence all 3 daily:

• Primary: prevent leaks, keep ventilation working
• Secondary: avoid loss of Ex integrity (glands, seals, repairs)
• Tertiary: must not bypass or block explosion vents/suppression

❗Incorrect maintenance can destroy any layer instantly.

Inspection / Ex Authorized Persons / Competent Persons

Their role requires understanding all 3 because:

• They verify primary controls exist and function
• Inspect secondary protections (Ex equipment) per IEC 60079-17
• Check tertiary measures (clear explosion vents, isolators, barriers)

❗If inspectors understand only the "Ex equipment" part → 50% of risks remain undetected.

HSE / Risk / Compliance Officers

Must ensure the entire explosion protection concept is coherent:

• Primary → part of risk reduction
• Secondary → part of legal conformity (ATEX/IECEx)
• Tertiary → part of emergency mitigation

❗If HSE views explosion protection only as "equipment category compliance," they miss prevention and consequence reduction.

CEOs / Insurance / Regulators

Understanding all 3 layers allows:

• Better risk prioritization
• Evaluation of compliance
• Reduced liability and premium

❗Lack of understanding leads to noncompliance, fines, or denied insurance claims.

Keep up good work!

Arpad
veress@exprofessional.com