Due to industrial explosions, every year, many lives are lost, and it causes above 200 billion dollars in losses in the global economy annually. Each explosion happened due to some negligence. So, you should have to make strong protection policies to avoid these explosions.
By following the policies, you can protect every individual, asset, and the integrity of your corporation. You know, Prevention is more important than reaction; it’s not just a saying but a moral duty. Learn more about what you can do to be safe by finding out about seven proven techniques. Don’t risk ruining your company’s reputation. Keep learning!
Strategy 1: Accurate Hazardous Area Classification (Zone Classification)
Well, the very first step in ensuring explosion protection is to identify the regions of risk failure. The hazardous area classification aids in determining areas where flammable gasses, vapours, or even dust might produce a threat. This ensures that the selection of equipment, and following the safety measures to deal with the hazardous area are necessary to avoid explosion.
ATEX, IECEx (for Europe), and NEC (for the USA) have specific criteria for classifying an area depending on the presence and concentration of potentially explosive gases, vapours, or even dust.
According to the ATEX/IECEx model, hazardous areas are divided into Zones:
- Zone 0: An area where explosive gas is present continuously for over long periods.
- Zone 1: An Area where explosive gas is likely to occur in normal operations.
- Zone 2: An area where explosive gas is unlikely in normal operations but possible for short durations.
For dust environments:
- Zone 20: Dust is present continuously.
- Zone 21: Dust is likely to be present in normal operations.
- Zone 22: Dust is unlikely but may occur occasionally.
According to America’s National Electric Code, gas falls under Class I while dust falls under Class II. Moreover, Division 1 represents high-risk areas while Division II shows comparatively lower-risk zones.
Making a mistake while classifying could result in outfitting the space which dramatically increases the chance of explosion. Hence, precision in classification should be emphasized.
Hexlon’s explosion protection equipment complies with ATEX and IECEx standards and is appropriate for Zone 1 & 2 (gas zones) and Zone 21 & 22 (dust zones). Enclosures, lighting, and junction boxes are designed for harsh industrial conditions where ignition must be prevented in classified areas.
Strategy 2: Strict Selection of Compliant Explosion-Proof Equipment
To make it clear, compliant explosion-proof equipment is that which follows the safety rules and standards and is certified. So, to stay protected it is important to select the compliant explosion-proof equipment. You know factors such as heat, dust, moisture, chemicals and many others can also affect the way equipment functions. There are various explosion proof equipments available in the market, like;
Hexlon’s Explosive-proof enclosures are specifically designed to handle the hazardous situation. 316 stainless steel materials which are strong and corrosion resistant materials. The ex-proof equipment made of these materials is best suited for harsh environments. Stainless steel helps to decrease the failure of equipment and increases the chances of durability.
b) Explosion-proof junction box
Another vital product of Hexlon among various is the explosion-proof junction box. As the name suggests, they serve the purpose of shielding the inner senses of the wiring connections of the enclosures. A good box must have a sealed strong structure where gas and dust cannot pass through.
Hexlon tries to apply technical knowledge to design explosion-proof enclosures and junction boxes to withstand these specific challenges. We focus on-field performance. So, we use durable materials and smart designs for good results. We also perform laboratory tests to prove the best performance.
Strategy 3: Regular Maintenance and Hazard Inspection
Regular maintenance is needed for explosion-proof equipment just like any other functional gadget. Lack of such maintenance could lead to neglect proper checks which could compromise the integrity of the system.
Common Risks:
- Aging or Damaged Seals: Outdated flammable seals are explosive due to penetrating gaps in enclosures allowing the danger gas or dust to escape.
- Corroded Enclosures: Weakened corrosion can put enclosures at risk due to comprising the structure.
- Loose Wiring Connections: Gaps in the wiring or corroded connections can bring forth overheating or inconsistent equipment disposal along with other failures.
- Accumulated Dust and Debris: Reduced or hindered ventilation can further put the device at risk of overheating for prolonged.
- Damaged Fasteners: Weakened or rusted fasteners can lose the protective capability of the equipment.
Hexlon sought to solve the above maintenance issues:
The BMDX Series Explosion-Protected Distribution Box of Hexlon addresses these challenges with unparalleled ease:
+ Modular structure: Makes the inspection individualized making it simple and paving way to effortlessly put the puzzle back together post-maintenance.
+ IP66 Protection Rating: The enclosure is protected from dust and powerful jets of water, preventing any compromise of structure.
+ Durable Construction: These materials ( like aluminium or stainless steel ) are made to withstand corrosion, harsh conditions, and other industrial-grade abuse.
Incorporating Hexlon’s BMDX Series explosion-proof Distribution box increases safety and reduces the risk of explosion-related incidents.
Strategy 4: Employee Training and Safety Culture Development
Even with the best quality explosion-proof equipment, no doubt, human error can lead to hazardous incidents. Moreover, tools are often mismanaged due to a lack of training and steps are neglected because of lack of guidance. Hence, a safety training culture is important for explosion protection.
Training should be properly arranged to educate the workers about their safety. Yes! workers must learn how to operate explosion-proof features, right? Well, they also must learn how to install, use, and maintain them. Moreover, they should also be trained on how to act in emergency situation, alright!
There will be a strong safety culture when everyone, from front-line personnel up to managers, cares about safety. To be hoest, safety should go beyond words in a manual to something operationalized within the day-to-day activities of an organization. When people care about safety, they work more carefully. Moreover, they also speak up when they spot issues.
Hexlon’s explosion-proof lightning:
Proud to say that Hexlon helps support this with smart design. Our explosion-proof lighting uses wireless technology that greatly simplifies the tasks of installation and maintenance. The ability for the worker to more easily and quickly attach the lamp body to the mounting components adds to the efficiency of numerous steps. The system permits interchangeable mounting accessories, which is a further improvement in speed and accuracy.
There are very few human will errors when a company follows these three rules: Effective training, well-defined policies, and advanced technology. Forming new rules is no longer the goal; instead, we should create strong habits and develop situational awareness. So, overall, we can say that a well-trained team and using the right equipment are among main factors to protect from explosions.
Strategy 5: Real-Time Monitoring of Dust and Gas Leaks
In explosive areas, the most prominent risk is gas or dust accumulation. The air is riddled with so much volatile mixture that a single spark can cause life-ending explosions within seconds. This is the reason why real-time monitoring is so useful. It empowers you to do something before anything uncontrollable happens.
In this case, real-time sensors are your best friend as they keep a keen eye on the air throughout the day and night. Such sensors in case of detecting danger signal alerts, enable workers to take soothing measures like halting work to rectify the issue and remain safe.
Hexlon’s technologically advanced explosion-proof equipment has found a wide array of applications in high-risk areas. Have you heard about the China-Russia East Route Gas pipeline project? Well, the East-Route Natural Gas Pipeline running between China and Russia exceeds 5000 kilometres. It stands as an important infrastructure for providing natural gas to different regions in China. Such risky areas necessitate the implementation of monitoring systems to safeguard and avert environmental catastrophes.
The sensors located on the pipeline were capable of detecting gas leaks immediately after they occurred. Employing such monitoring technologies goes beyond fulfilling safety requirements. One has to be proactive towards the risks. The earlier you are notified about the issue, the better prepared you are to manage it.
Strategy 6: Optimizing Equipment Heat Dissipation and Temperature Resistance
Heat is often not regarded seriously, yet it has the potential to serve as a deadly catalyst in dangerous environments. A large number of industrial tools and machines operate and dissipate some form of heat. You know an excessive amount of the heat built up can cause an explosion or fire.
So, exhaust systems do help with temperature control, so controlling heat does become a major concern while trying to prevent explosions. The equipment used in these areas has to withstand heat, well, it is obvious that a good design takes care of dissipating heat and stops its build-up. So, Effective heat dissipation and high-temperature resistance are crucial for maintaining safety.
Keeping high risk in mind, Hexlon’s explosion-proof lighting fixtures are designed with the following considerations.
- Aluminum Alloy Housing: They comprise housings of high-class aluminium alloy which have remarkable conductive and dissipative properties towards heat.
- ATEX and IECEx Certified: Lights have international safety approvals which allow use of the fixture in places with explosive atmospheres.
- Constructed for Versatility: Lights can be used in Zone 1 and Zone 2 hazardous areas. Suitable for oil and gas industries, chemical plants, and mining industries.
By applying Hexlons explosion-proof lighting, plants can better maintain safety through proper control of high-heat environments in dangerous places.
Strategy 7: Establishing Emergency Response and Redundant Systems
Every machine has its vulnerabilities and none is failsafe. The most optimally designed machinery can break down and malfunction. Which is exactly why it is essential to have an alternate plan. In any scenario where an explosion is a possibility is precisely where contingency plans and emergency response protocols are useful.
Having a plan B is the definition of redundancy. In case one part fails, another will take its place thereby maximally reducing time wasted addressing the concern at hand, and ensuring the site remains safe. It is a failsafe for reducing the chances of an explosion resulting from machinery breakdowns or mere unexpected equipment events.
a) Explosion-Proof Redundant Systems
Hexlons explosion-proof junction boxes provide customizable cable entry configurations, allowing for simplified wiring and dual-system layouts. Critical safety is added to ensure backup functionality.
b) Emergency Lighting with Backup Power
Internal emergency battery packs of Hexlon emergency lighting systems ensure maintained illumination which is critical in the case of power outages. Visibility is imperative in guiding personnel towards the safest zones.
These measures strengthen safety infrastructure at a facility’s core and greatly enhance robust emergency and redundant systems to be able to avert the danger of explosions and damage to employees and assets.
Conclusion
Accidents caused by industrial explosions are fatal and so should follow a safety plan. Ignored measures or a slight mistake can result in serious harm. These seven strategies are tested best practices whose astonishing effectiveness may be seen as shocking. They increase risk measures and minimize loss exposure. Keep following the measure! Stay safe!
