Introduction
In the gas industry, safety is not merely an important consideration—it is a fundamental operational requirement. The presence of LPG (liquefied petroleum gas), flammable substances, and hazardous areas means that every piece of equipment must comply with stringent technical and safety standards. This is especially true for industrial weighing systems, which play a critical role in logistics, loading operations, inventory management, and commercial transactions.
Weighing in hazardous environments requires a completely different approach from that used for conventional weighbridges operating at standard industrial facilities. A single improperly designed electronic component, an overheating device, or even an electrostatic discharge can pose a serious ignition risk. For this reason, explosion protection becomes one of the primary design considerations alongside weighing accuracy when developing such systems.
Metripond-M93 designed and installed a 60-tonne, 18-metre ATEX-certified weighbridge for operation in a gas industry environment, specifically for weighing LPG road tankers during the filling process. What makes this project particularly noteworthy is not only its explosion-proof design, but also its ability to support automated filling process control while fully complying with the most stringent ATEX requirements.
Why Does Weighing in the Gas Industry Present Unique Challenges?
In gas industry environments, system designers must continuously account for the risk of explosion. Due to the presence of LPG, filling stations, gas collection facilities, and tank handling systems are often classified as ATEX hazardous areas.
In such locations, the use of conventional electrical equipment can pose a significant risk. Standard weighing systems may introduce several potential ignition sources, including electrical arcs, overheating components, and electrostatic discharge.
Weighing in hazardous environments requires specialized engineering solutions designed to minimize the risk of ignition. ATEX-certified weighbridges are specifically developed for this purpose.
In the gas industry, however, safety is not the only priority—continuous and accurate operation is equally critical. During the filling of LPG road tankers, measurement inaccuracies can lead to substantial financial losses, while overfilling may create serious safety hazards.
Project Overview: A 60-Tonne ATEX Weighbridge for LPG Road Tankers
The explosion-proof weighbridge installed by Metripond-M93 was designed for a gas collection facility where LPG road tankers are weighed during the filling process.
The system consists of a:
- 60-tonne weighing capacity
- 18-metre-long
- elevated, ramp-type
- reinforced concrete
- ATEX-certified weighbridge
The weighbridge is located in a Zone 1 hazardous area, which requires enhanced explosion protection measures. In such environments, it is essential that every component of the system complies with applicable ATEX standards and regulations.
One of the project’s key technical features is the separation of the weighing and control functions. While the load-receiving structure of the weighbridge is installed within the ATEX zone, the data processing and control electronics are located outside the hazardous area, significantly reducing potential ignition risks while ensuring safe and reliable operation.
How Does the Explosion-Proof Weighing System Operate?
Load-Receptor Installed in the ATEX Zone
The weighbridge’s load-receiving structure is located directly within the hazardous area. This component is responsible for detecting the vehicle’s weight and transmitting the measurement data.
A key design principle of the system was to ensure that only the components strictly necessary for the weighing process remain within the hazardous zone. This significantly reduces the number of potential ignition sources and enhances overall operational safety.
Control Electronics Located in a Safe Area
One of the system’s major advantages is that the data processing and control electronics are installed outside the ATEX zone.
The main weighing indicator, Zener barriers, network switch, and optical converters are housed in a weather-protected 600 × 800 mm enclosure located in a safe area. This configuration not only supports explosion protection requirements but also simplifies operation, maintenance, and servicing.
Ex-i Secondary Display for the Driver
An important feature of the system is the intrinsically safe (Ex-i) secondary display installed within the ATEX zone.
This allows the truck driver to continuously monitor the filling process and weighing data without compromising the safety of the system.
The solution simultaneously improves:
- operational safety,
- ease of use,
- workflow efficiency,
- and filling accuracy.
Automated Filling Process Control
Modern gas industry weighing systems are no longer limited to measuring weight alone. In many applications, the weighing system also plays an active role in controlling technological processes. In this project, several communication interfaces of the DD700I weighing indicator were utilized to support process automation.
Through its 4–20 mA output, the weighing indicator directly controls the filling process. Based on predefined filling setpoints, the system automatically initiates and stops the filling operation at the required weight thresholds.
This provides several significant advantages:
- reduces the risk of human error,
- enables more accurate filling,
- increases process efficiency,
- and improves operational safety.
In the gas industry, these benefits are particularly important, as overfilling or inaccurate dosing can result in serious safety risks and operational issues.
Specialized Materials for Hazardous Environments
Material selection plays a critical role in the design of explosion-proof weighing systems. For this project, the reinforced concrete weighbridge was constructed using a special spark-resistant dolomite concrete that is resistant to oil and condensate exposure.
This provides several important benefits:
- reduces the risk of mechanical spark generation,
- withstands aggressive industrial environments,
- ensures a long service life,
- and maintains stable performance under heavy loads.
Gas industry facilities are frequently exposed to oil residues, moisture, and condensate, all of which can place significant long-term stress on structural components. Choosing the right construction materials is therefore not only a matter of safety but also a key factor in ensuring long-term reliability and cost-effective operation.
The Role of Bilanciai CPR-M C4 Ex Load Cells in Accurate Weighing
Load cells are among the most critical components of any industrial weighing system. These devices convert mechanical force into measurable electrical signals, forming the foundation of accurate weight measurement.
For this project, premium-grade Italian-made Bilanciai CPR-M C4 Ex laser-welded load cells were installed. In the gas industry, measurement accuracy is not merely a matter of commercial accounting. Correct filling quantities directly affect safety, logistics efficiency, and overall operational performance.
Digital Data Processing and the Portaprogram Software System
Modern industrial weighing is closely integrated with digital data management and automated reporting. In this project, weighing data is processed by a PC connected to the weighing indicator via an Ethernet network.
Using the Portaprogram software system developed and implemented by our team, users can generate:
- statistical reports,
- data tables,
- graphical analyses,
- weigh tickets,
- and a wide range of operational reports.
This significantly simplifies:
- administrative processes,
- data traceability,
- logistics analysis,
- and corporate reporting.
Digitized weighing systems are becoming increasingly important in modern industrial operations, particularly in environments where accuracy, transparency, and traceability are essential requirements.
Why Is an ATEX Weighing System Beneficial for the Gas Industry?
One of the most important advantages of explosion-proof weighing systems is improved operational safety. ATEX compliance reduces the risk of explosions and supports safe, reliable operation in hazardous environments.
In addition, these systems provide significant economic benefits:
- more accurate filling processes,
- reduced product losses,
- faster operations,
- automated process control,
- fewer human errors,
- and longer service life.
In gas industry applications, it is particularly important that weighing systems deliver stable and reliable performance over the long term.
Which Industries Can Benefit from Similar ATEX Weighing Systems?
Although this project was specifically developed for a gas industry application, ATEX-certified weighbridges play a vital role across many other industries. Explosion-proof weighing solutions may be required wherever flammable gases, vapours, solvents, or combustible dust can create a potentially explosive atmosphere.
The chemical industry is a typical example. Various solvents, alcohols, flammable chemicals, and reactive substances are routinely handled in production facilities. Whether for incoming raw materials, tanker weighing operations, or process control applications, ATEX compliance is often a fundamental requirement. In such environments, an explosion-proof weighbridge supports not only accurate measurement and accounting but also the safe operation of the entire facility.
The oil and fuel logistics sectors represent another major application area. Refineries, fuel terminals, tank farms, and logistics centres are continuously exposed to flammable gases and vapours. In these environments, weighing systems must meet the same explosion protection standards as pumps, valves, and other process equipment.
The pharmaceutical industry may appear less obvious at first, yet certain manufacturing processes can present a significant dust explosion risk. This is particularly relevant when handling, dosing, or transporting powdered raw materials. In addition, pharmaceutical operations require exceptionally high standards of measurement accuracy and documentation, making ATEX weighing systems combined with automated data processing solutions especially valuable.
Certain segments of the food industry may also require explosion-proof weighing technology. Fine particulate materials such as flour, sugar, starch, and similar ingredients can create combustible dust atmospheres during handling and processing. Many facilities only become fully aware of this risk during detailed safety assessments or compliance audits.
ATEX weighing systems can also be applied in:
- paint and coating manufacturing,
- chemical storage facilities,
- biofuel production environments,
- plastics raw material handling operations,
- and hazardous waste treatment facilities.
As explosion protection becomes an increasingly important aspect of modern industrial operations, ATEX compliance is no longer solely a safety requirement—it is also a key factor in long-term operational reliability and economic efficiency. A properly designed explosion-proof weighing system not only satisfies regulatory requirements but also contributes to more stable operations, improved logistics performance, and reduced operational risk.
Frequently Asked Questions About ATEX Explosion-Proof Weighbridges
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What Is an ATEX Weighbridge?
An ATEX weighbridge is an explosion-proof industrial weighing system specifically designed for safe weighing operations in hazardous environments. These systems comply with European Union ATEX regulations and are engineered to ensure that they do not become a source of ignition during operation.
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What Does a Zone 1 Classification Mean?
Zone 1 is a hazardous area where an explosive gas atmosphere is likely to occur occasionally under normal operating conditions. Only equipment with the appropriate ATEX certification may be used in such environments.
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Why Can’t a Conventional Weighbridge Be Used in Hazardous Areas?
The electronic and mechanical components of conventional weighing systems can act as potential ignition sources. Electrical arcs, overheating components, or electrostatic discharge may be sufficient to trigger an explosion in the presence of flammable gases or combustible dust.
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Why Is the Weighbridge Control Electronics Installed in a Safe Area?
One of the most important explosion protection measures is to keep potentially hazardous electronic components outside the hazardous area. This significantly reduces the risk of ignition while also simplifying maintenance and servicing.
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What Is the Purpose of 4–20 mA Communication in the Weighing System?
The 4–20 mA interface is an industrial automation standard. Through this connection, the weighing system can control the filling process by automatically starting and stopping filling operations according to predefined weight limits.
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What Are the Benefits of an Ex-i Secondary Display?
The intrinsically safe (Ex-i) secondary display allows truck drivers to safely monitor weighing and filling data directly near the hazardous area without compromising system safety.
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Why Is Special Dolomite Concrete Important?
Spark-resistant dolomite concrete that is resistant to oil and condensate contributes to both explosion protection and long-term durability. In harsh industrial environments, it significantly improves the reliability and service life of the weighing system.
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Which Industries Commonly Use ATEX Weighbridges?
Explosion-proof weighing systems are most commonly used in the gas, chemical, oil and gas, pharmaceutical, and fuel logistics industries.
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Why Is Accurate Weighing Important When Filling LPG Road Tankers?
Accurate weighing is not only an economic consideration but also a critical safety requirement. Overfilling or inaccurate dosing can increase operational risks while causing significant product losses.
