In every job where there is a risk of flammable gases, dust, or vapors, safety is a must. One way to enhance these environments’ safety is with explosion-proof fittings. The main purpose of these special elements is to prevent the ignition of potential hazards like flames and sparks. In this blog, we will look into explosion-proof fittings in complete detail, their standards, their main areas of utilization, and the regulations that make them important for safe and injury-free operations.
Explosion-proof Conduit Outlet Boxes
1) What is explosion-proof fitting?
“Explosion-proof are connectors that are made specifically to be used in potential hazards where there are risks of ignition such as gas, vapors, or dust.”
Blastproof fittings are made with one goal in mind: to ensure that the flammable external atmosphere never comes into contact with the hot, cloudy, or flame-filled interior of electrical appliances. Contrary to what the name suggests, entirely preventing an explosive reaction is not something these fittings are designed to do. Rather, they are tailored to manage and secure the blast within a specific zone and away from others.
Fittings that are explosion resistant, are otherwise referred to as ex-proof fittings or explosion-proof fittings. In modern industries such as oil and gas, chemical processing, minimalistic construction, mining, and especially manufacturing industries these fittings are said to be in use. This is because hazardous conditions are a normal part of their work processes.
You should know that these fittings are constructed to strict safety guidelines and generally meet certification requirements by ATEX, IECEx or UL. The components are tested and manufactured of great strength and should be able to withstand corrosion. It makes it easier to work with them since they have to work in tough conditions.
2) Standards and Compliance
➔ IECEx Certification
The explosion-proof electrical conduit fittings have to meet an international standard which the International Electrotechnical Commission System standardises for Certification to Standards Relating to Equipment for Use in Explosive Atmospheres (IECEx). This also makes trade between countries a lot easier as all the parties know what the international requirements are. Moreover, this ensures peace of mind when acquiring these components.
➔ ATEX certification
ATEX stands for atmosphere-explosive, this term originated from the EU standard. This directive is also broken down into two main directives:
- Directive 2014/34/EU: Covers equipment and protecting systems.
- Directive 1999/92/EC: Highlights focus placed on employees and potential risks as well as dangers in workplaces.
- Hazardous Zones
Depending on how often they are present in the atmosphere and for how long, hazardous zones are divided into zones. There are also ways of classifying explosion-proof fittings in order to make them appropriate for all the zones.
| Zone | Description | Example |
| Zone 0 | Presence of explosive gases or vapors | Inside fuel tanks |
| Zone 1 | Chances of explosive atmosphere to occur during normal operation. | Near refinery vents |
| Zone 2 | An explosive atmosphere is possible for short periods. | Surrounding gas pipelines |
| Zone 20 | Indicates continuous presence of explosive dust. | Grain silos |
| Zone 21 | Explosive dust may occur during normal operation. | Near flour mills |
| Zone 22 | Explosive dust is unlikely during normal operations but may occur for short periods. | Surrounding sugar processing plants |
- Why do Standards and Compliance matter?
The confidence that explosion-proof pipe fittings will function correctly follows the knowledge that they were built up to IECEx and ATEX standards. It implies thorough testing to eliminate any risks of ignition. This means there are:
- Safety during Operations: Protection of the people and the machinery.
- Legal Compliance: With respect to local and global requirements.
- Global Usability: Simple adaptation in various markets.
3) Types of explosion-proof fitting
Shell fittings, where the inside wall has been coated with an explosive-preventing layer, have essentially been designed for use in zones which have explosive materials. Sealing fittings, elbows, tees, and cable glands are some of the most widely used explosion-proof fittings.
i) Sealing Fittings: Sealing fittings we can say where flammable gases and unreliable earth particles are supposed to be initially prevented. It reduces the risk of generating an electrical spark that may develop along the conduit. It is to be installed where a cable enters or exits an electrical box or any equipment.
ii) Elbows and Tees: It is used to ensure that the electrical conduits of the building are changed at the angle of elbows or tees to eliminate the chances of explosions. These parts do not compromise by allowing conduits to turn elbows or rotate at 90 degrees, but by branching cables through tees. Electrical layouts with these fittings are made up of rather more intricate shapes and layouts.
iii) Cable Glands: Cable glands/cable entry devices are one of the most critical devices used in securing the entry points of cables into electrical machines. These fittings aid in securing the cables by providing an entry seal. Moreover, it also aids in the protection of the internal equipment from the penetration of dust, dampness and combustible gases. These attachments come in different dimensions and designs so that particular cables can be fitted.
iiii) Flexible Conduits: Suitable for applications where flexible connections are required, such as vibrating equipment, mobile units, etc. Made of metal bellows or PVC covered pipe. Suitable for oil and gas, chemical, coal mine and other industries.
4) Applications of explosion-proof fittings
Explosive proof or resistant fittings are particularly important in those industries which require the handling of dangerous and easily explosive materials. Below are eight key applications of these fittings:
- Oil and Gas: Explosive-proof fittings are used in oil and gas facilities, including drilling adheres and refineries. It is so that the electrical installations within those facilities do not end up causing an explosion by sparking or flames.
- Chemical Plants: Chemical plants utilize explosive-proof fittings on plants that deal with potentially volatile and flammable chemicals and gases. You know some of these chemicals may cause an explosion when an electrical source is applied.
- Manufacturing: These fittings are also used in manufacturing units use combustible dust, powders or fumes. These fittings help to ensure that electrical units do not become sources of ignition sparking.
- Mining: Mining activities, particularly those conducted underground, necessitate the use of explosion-proof parts in electrical devices. These fittings avoid the outbreak of explosive gases and dust which are usually found in mines.
- Pharmaceutical: Explosion-proof conduit fittings have a place in the production of drugs as they prevent accidents in spaces where flammable solvents and powders are present.
- Marine: In marine applications, for instance, offshore rigs and ships, the use of explosion-proof fittings prevents the ignition of the fuel vapour or gas.
- Aerospace: Fittings have a use in aerospace manufacturing and maintenance also. These fittings prevent electrical apparatus from igniting other flammable substances during safe operations in the hangars and aircraft facilities.
- Agriculture: Explosion-proof electrical fittings are installed in agriculture infrastructures such as grain storage and milling. Fittings avoid the ignition of dust particles that could cause explosions in such sensitive places.
5) What are the benefits of explosion-proof fittings?
Explosive environments exist in a majority of industries, and proper measures must be taken in order to operate safely. The use of explosion-proof fittings comes in quite handy in those places. Below are some of the benefits:
+ Enhanced Safety: The fittings offer a way to prevent accidents in places where dangerous gases, oils, and liquids may exist.
+ Protection of Personnel: Such fittings offer protection to the workers from being sparked into flames whenever they are exposed to places where flammable vapour is involved. You know explosions can occur leading to loss of life and destruction of property, so explosion-proof fittings are really appreciable.
+ Compliance with Safety Standards: Getting a pass in basic compliance such as IECEx and ATEX certification is really satisfying for fittings since they are considered explosion-proof. However, having such compliance aids businesses in averting legal fines.
+ Equipment Protection: As a rule, flame-free fittings should also protect electrical appliances from any malfunction. To be on the point, these fittings do not lead to the destruction of your valuable assets.
+ Enhanced Functional Consistency: These fittings are usually made of corrosion-free materials. Apart from this, their design guarantees low operational failures in high-risk environments.
+ Downtime Minimization: These fittings promote lower chances of equipment repairs or even stoppage of production due to explosions and fires. This results in fewer operational interruptions. Thereby, enabling enterprises to uphold productivity and evade expensive downtime.
+ Cost-Saving in the Long Run: Investing in explosive-proof fittings can be costly at first, but over time the cost will be justified. The fittings mitigate risks of machines being damaged, work-related injuries, and expensive maintenance which in the end offers reasonable returns.
6) Conclusion
Alright! So, the implementation of explosion-proof fittings is critical for making occupational environments safe from hazards when working in areas such as mining, chemical production plants, and petroleum and oil. They keep the personnel and the equipment safe from any burn sources or explosive incidents.
If you are seeking fittings which meet the standards of quality and reliability, look no further than Hexlon. Our product assortment includes fittings which comply with the strictest level of safety standards ideal for use in ATEX and IECEx-certified environments. Hexlonex products are designed to withstand harsh settings while improving safety reliability, compliance, etc. So, Hexlon is a wise choice for companies working in explosives risk industries.
