In industrial settings where flammable gases, vapors, or dust are present, ensuring the safety of electrical and electronic equipment is crucial. Faults in such equipment can generate heat or sparks, potentially igniting these substances and causing explosions. To prevent such disasters, three main safety systems are used: intrinsically safe, flameproof, and explosion-proof equipment. Understanding the differences between these systems is essential for choosing the right protection for specific hazardous environments.
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Electrical faults in areas with flammable gases can lead to heat or sparks that may ignite the gases, causing explosions. To prevent such incidents, equipment in these areas must adhere to strict safety standards. The three main approaches are intrinsically safe, flameproof, and explosion-proof equipment.
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Flameproof vs. Explosion Proof: “Flameproof” and “explosion-proof” are often used interchangeably. Both refer to equipment that contains explosions within a heavy-duty enclosure, ensuring safety by preventing flames or gases from escaping.
Also read – What is the difference between explosion-proof and flameproof?
Intrinsically Safe vs. Flameproof/Explosion Proof: Intrinsically safe equipment is designed to prevent explosions by limiting energy, making it inherently incapable of igniting flammable gases. In contrast, flameproof/explosion-proof equipment contains potential explosions within a robust enclosure. Intrinsically safe devices are lighter and easier to maintain, while flameproof/explosion-proof devices are heavier and better suited for high-power applications.
Choosing the right safety system depends on your specific requirements. Intrinsically safe equipment is ideal for low-power, portable devices and situations where live maintenance is necessary. Flameproof and explosion-proof equipment are better suited for high-power, permanent installations where containing an explosion is critical. Understanding these differences helps industries implement effective safety measures to protect workers and assets in hazardous environments.
For further guidance on selecting the right equipment, consult with Flameproof Instrumentation who can provide tailored solutions based on your unique needs.
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Although many topics in this article will refer to enclosures used for mounting various types of equipment, including switching, measuring, and control apparatus, it should be emphasized that this protection concept applies to a wide range of products. Below is a list of some of them:
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This protection involves the use of a special enclosure. It is allowed that an explosion may occur inside the enclosure, but it must not escape outside. However, for this protection to be effective, a series of restrictions must be met. Otherwise, the protection will be ineffective, posing a risk of a secondary explosion outside the enclosure.
Basic Assumptions of Ex d Protection:
What happens if the flame path is damaged, e.g., by various types of pitting or scratches? The protection loses its effectiveness, which poses a risk of a secondary explosion outside the enclosure, as shown in the animation below:
Different economic areas are based on different norms and standards. For example, in Europe, the primary document from which we derive knowledge about Ex d protection is the IEC -1 standard. In the case of North America, these are the UL or FM standards. As a result, there are certain differences in both terminology and key assumptions for Ex d explosion protection.
Let’s start with terminology, as its incorrect use can lead to serious errors. In Europe, devices with Ex d protection are referred to as flameproof, as per the IEC -1 standard. At the same time, devices intended for use in explosive zones (regardless of the protection they have) are commonly referred to as explosion-proof devices.
On the other hand, in North America, the term explosion-proof is reserved exclusively for devices with Ex d protection.
The differences in the terminology of devices with Ex d protection between Europe (flameproof) and North America (explosion-proof) are just the beginning of the list of discrepancies. Much more significant differences exist in the approach to the Ex d protection concept itself – some of which are presented in the table below.
A few years ago, a new concept of Ex d enclosure appeared on the market, the main advantage of which was supposed to be the reduction of weight, and thus the cost of the device. The new concept involved the use of a thin-walled enclosure with so-called flameless explosion venting. Its task is to reduce the pressure inside the enclosure by directing the explosion effects to the environment without the risk of transmitting the explosion outside. This concept, known for decades, has so far been used exclusively to protect process equipment such as silos, dust collectors, bucket elevators, etc.
This solution involves mounting a so-called decompression panel on one of the enclosure walls, which, when the explosion pressure reaches +/- 0.1 bar g, is deliberately ruptured, directing the explosion effects to the environment. However, to ensure this is done safely, behind the panel (viewed from the outside) is a kind of filter made of a suitable number of layers of steel mesh. Its role is to:
Residual pressure and exhaust gases cooled below the auto-ignition temperature of the explosive atmosphere escape to the environment.
Despite the interesting concept, this solution has not yet gained recognition among users, remaining just a curiosity.
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