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In industries where hazardous environments are part of everyday operations, safety and reliability are paramount. One critical component ensuring both is the  EX connector. These specialised connectors play a crucial role in various applications where explosive atmospheres are present, such as oil and gas, chemical processing, mining and more. Here, Isaac Noble,  European product manager at connector specialist PEI-Genesis, delves into the applications and benefits of EX connectors and new developments with Hermetic EX connectors.

EX connectors are a subset of connectors specifically designed to meet the stringent requirements of hazardous locations classified as explosive atmospheres. When choosing connectors for hazardous missions, there are several key factors that should be considered. First, consider the different Zones connectors will be used in.

In the Dangerous Substances and Explosive Atmosphere Regulations 2002 (DSEAR), Zone 0 is defined as a constant explosive environment, Zone 1 indicates there is often an explosive atmosphere and Zone 2 is indicative of a rarely explosive atmosphere.

The UK Health and Safety Executive (HSE) explains, “the primary purpose of zoning is to facilitate the proper selection and installation of apparatus to be used safely in that environment, taking into account the properties of the flammable materials that will be present.”

In a worst-case scenario, it is possible that electricity running through connectors could become an ignition source if it comes into contact with flammable dust and gases in the environment or the surface or the connector reaches the ignition point of the gases and dust’s in the atmosphere. For this reason, all connectors used in explosive atmospheres must comply with the IECEx international standard which governs the installation and use of electrical equipment in these environments. 

Benefits of hermetic EX connectors

One notable feature of Hermetic EX connectors is their capability to uphold pressure via a hermetic glass-to-metal seal, all while meeting the necessary ATEX and IECEX requirements essential for deployment in hazardous environments. In dangerous environments where flammable gases, vapours, or combustible dust are present, even a small spark or uncontrolled temperature source can trigger an explosion or fire. All gases and dusts have an ignition point and by controlling and limiting the temperature the surface and internal connection can reach hermetic EX connectors significantly enhance safety for personnel and in addition allowing applications requiring pressure tolerance through the connector to maintain these standards.

At the same time, hermetic EX connectors feature a sealed enclosure that effectively protects the internal electrical components from exposure to the surrounding hazardous atmosphere. This sealing mechanism prevents moisture, dust and other contaminants from infiltrating the connector, ensuring consistent and reliable electrical performance over time.

Many hermetic EX connectors are also constructed from corrosion-resistant materials such as stainless steel or specialised alloys. This corrosion resistance helps maintain the integrity of the connector in harsh and corrosive environments commonly encountered in industries like oil and gas, chemical processing, and mining.

These types of connectors are designed and manufactured to comply with stringent industry standards and certifications for use in hazardous locations. These standards, such as ATEX (European Union), IECEx (International), NEC (National Electrical Code) and others, establish requirements for equipment intended for use in explosive atmospheres. Compliance with these standards ensures that hermetic EX connectors meet the necessary safety criteria and regulatory requirements.

The reliability and durability of hermetic EX connectors contribute to reduced downtime associated with equipment failure or maintenance. By providing a secure and consistent electrical connection up to the task of withstanding pressure up to 50bar; these connectors minimise disruptions to operations in hazardous environments, thus increasing productivity and efficiency.

Hermetic EX connectors are also used to protect sensitive electrical components from exposure to corrosive substances, moisture, and other environmental factors that could accelerate equipment degradation. As a result, equipment installed with Hermetic EX connectors may experience a longer lifespan, reducing the frequency of replacements and associated costs.

Applications for EX connectors and hermetic EX connectors

EX connectors are employed in drilling rigs, wellhead equipment, and production platforms to provide reliable electrical connections in areas where flammable gases may be present. These connectors ensure safe operation and prevent the risk of igniting potentially explosive atmospheres during drilling, extraction, and processing activities.

Refineries and petrochemical plants rely on EX connectors within crucial equipment like pumps, compressors, and instrumentation, strategically positioned in areas prone to flammable vapours. These connectors ensure uninterrupted communication and control, mitigating the risk of ignition in potentially explosive environments. Moreover, Hermetic variants find extensive application in turbo generators and expanders employing magnetic bearings, pressurised actuators, and LNG pumps, reinforcing safety protocols across various industrial processes.

In mining operations, where dust and methane gas pose significant hazards, EX connectors play a pivotal role in safeguarding equipment such as conveyors, crushers, and ventilation systems. By eliminating the risk of sparks, these connectors maintain operational safety amidst potentially explosive atmospheres, enhancing the reliability and longevity of mining operations.

Additionally, the versatility of EX connectors extends to railway and automotive sectors, where the presence of flammable fuels or gases demands meticulous electrical connectivity. These connectors facilitate secure electrical connections in fuelling systems, engine controls, and onboard electronics, ensuring uninterrupted performance while prioritising safety standards in transportation applications.

EX connectors play a vital role in ensuring safety and reliability in hazardous environments across various industries, including oil and gas, mining, and transportation. By providing sealed, spark-free electrical connections, these connectors mitigate the risk of ignition in explosive atmospheres, safeguarding personnel and equipment while enabling efficient operations in challenging conditions.

PEI-Genesis is an ATEX-approved assembler of the Amphenol Star-Line EX and Amphe-Ex, which are arguably the most popular EX connectors in the world due to their sturdy design and plethora of configuration options. With a broad range of reversible inserts; solder, crimp and pressure terminals; and flexible cable options, Star-Line EX connectors will meet application demands in petrochemical refineries, land and offshore drilling systems.

To find out more about PEI-Genesis’ connector solutions for hazardous environments visit www.peigenesis.com.

British Safety Council concerned at continued rise in work-related deaths in Britain

Commenting on the latest Health and Safety Executive data, showing a rise in work-related deaths in Great Britain for the second consecutive year, Dr Julie Riggs, Director of Education and Membership, British Safety Council, said: "The rise in work-related fatalities, as reported by the Health and Safety Executive, serves as a stark reminder that we cannot become complacent about the health and safety of workers. Put simply, the consequences of poor health and safety are too great a price to pay.

"For 50 years, the general direction of travel has seen safer workplaces with falling numbers of workplace deaths and non-fatal injuries; that for a second year this trend has reversed is cause for concern. It sends a message that we need to prioritise worker health and safety, understand the causes of rising fatalities, and take targeted action to return to falling figures and safer workplaces for all."

British Safety Council’s networks: 
Website:                         www.britsafe.org 
Twitter:                           www.twitter.com/britsafe 
Facebook:                     www.facebook.com/britishsafetycouncil 
YouTube:                       www.youtube.com/britishsafetycouncil 
LinkedIn group:            www.linkedin.com/company/british-safety-council 
Safety Management:  https://sm.britsafe.org 

Four Speedor high-speed doors have been installed by Hart Door Systems at a major frozen and cooked meat manufacturing in northern England. The doors, at just 1.5m wide and 1.95m high, are the second smallest Speedors ever manufactured by Hart.

“The contract demonstrates two things,” says Gordon Kipling, regional sales manager for Hart. “Not only is our Speedor range available in distinctly different types of doors but where applicable the doors can be available in reduced sizes for precise requirements.

“In this case there was a need to protect the production environment against drafts, humidity, dust and dirt by installing our Speedor Cleanroom with its fast opening and closing speed. Our pharmaceutical standard Cleanroom Speedors control airflow thus reducing contaminants.”

Designed specifically for manufacturing and research facilities, Speedor Cleanroom works in strictly controlled environments where hygiene standards are high, such as pharmaceuticals, food processing, electronics and micro-mechanics industries.

The main features of Speedor Cleanroom include maintaining strict air leakage requirements over specified pressure differentials. Complete with an intelligent control panel with digital display each Cleanroom has a reliable and clean in-line drive system complete with an integral safety brake and a non-touch safety light curtain ensures maximum protection to personnel.

Seals minimise pressure drops and protect the manufacturing environment against drafts, humidity, dust and dirt.

www.hartdoors.com

Automated Methane Monitoring Solution with OGI by FLIR delivers 24/7 Coverage of Methane Production, Transmission and Storage Infrastructure

AirTower AT is designed to clean ambient factory air, removing the remaining pollutants that existing extraction is failing to capture.Full hall extraction assists extraction systems, removing coolant mist, smoke, and weld fume from the workplace.Designed to extract at high level, where weld fume and atmospheric pollution settles; returning clean air to the working space at low level to create a healthier working environment.AirTower from AirBench uses high power, energy efficient EC fans alongside a filter system selected to suit your application, to clean high volumes of air.Alongside our dust, fume, and mist extraction systems, the new AirTower AT helps you create the right working environment.

Contact us to arrange a site survey.

www.airbench.com

Working pressure tolerances of 90% - now also for high-pressure applications > 400 bar g.  

The HPRRD reverse rupture disk offers a durable and sustainable solution for high-pressure applications with pulsating process conditions. The new design dispenses with predetermined breaking notches or other mechanisms that impair fatigue strength.   The compact design requires no additional support structures and guarantees direct installation in the on-site installation system. Independent and flexible machining of the outer contour allows unlimited freedom for the connections and sealing surfaces.  

Burst pressures from 400 to 4000 bar g with a tolerance of up to ± 2 % of the nominal burst pressure can be realized thanks to consistently precise manufacturing and guarantee a reliable safety function from -5 to 350 °C. 

When triggered, the bursting diaphragm ruptures as a whole and releases the entire relief cross-section. This enables the process pressure to be relieved safely and quickly. 

The unnotched design of the new ST-HPR high-pressure reverse rupture disc enables high pulsating working pressure tolerances of 90 %. As the first reverse rupture disc in the REMBE® universe, no mechanical weakening by blades, for example, is required for opening. The compact design and machining from solid material guarantee almost limitless freedom of shape of the outer contour - whether conical or flat sealing. Burst pressures of 400 to 4000 bar g with a tolerance of up to ± 2 % of the nominal burst pressure can be achieved through consistently precise manufacturing and guarantee reliable opening behavior from -5 to 350 °C. When triggered, the bursting diaphragm ruptures as a whole and releases the entire cross-section. This enables the process pressure to be relieved safely and quickly. 

Fig. 1: REMBE rupture disk for pulsating high-pressure applications

Given the expected and necessary growth of the hydropower industry over the upcoming decades, it could be argued that polymeric technology has a valuable role to play in supporting this growth. Applications, such as the one identified below, demonstrate how assets that would otherwise be decommissioned or sent to landfill can be given a new lease of life thanks to a combination of epoxy repair composites.

Introduction:

Traditionally known for its high performance repair and maintenance solutions, Belzona is expanding its reach into the Original Equipment Manufacturer (OEM) market.

With an extensive range of coatings, Belzona can provide cost-effective alternatives for protecting and finishing OEM equipment such as pumps, tanks and heat exchangers.

One of 14 OEM Heat Exchangers coated with Belzona

Rather than waiting until the damage is done, a large Manufacturer of heat exchangers in the Czech Republic specified the use of Belzona to enhance the durability and performance of their newly manufactured equipment. The Customer reached out to Belzona Authorised Distributor, STROJCONSULT Litvínov s.r.o. for a solution.

Why Chose a Belzona Coating?
After learning about the benefits of Belzona 1593, the Company decided to coat all 14 newly fabricated heat exchangers to prevent corrosion and prolong the equipment's lifespan.

Each heat exchanger was lined with two coats of Belzona 1593, a high temperature brush-applied epoxy coating which provides corrosion protection for equipment operating under continuous immersion conditions. The team at Stroj Consult not only supplied the Belzona solution but also provided an expert team of applicators to complete the lining. The application was completed over a 14-day period offering the customer a comprehensive turn-key service.

Belzona proudly announces the launch of its revolutionary SF₆ Leak Solution.

As the world grapples with the urgency of minimising greenhouse gas emissions, Belzona takes a proactive stance by introducing its solution to SF₆ leakage. Belzona SF6-FIX can reduce leaks to undetectable levels, mitigating the environmental hazards associated with SF₆ usage.

What is Sulphur Hexafluoride (SF₆)?

Sulphur hexafluoride or SF₆ is a synthetic gas comprised of one sulphur and six fluoride atoms. It is commonly used in medium and high voltage electrical equipment to insulate live electrical parts and to switch the flow of electrical current on and off. This same equipment, crucial for the efficient functioning of power grids, also plays a pivotal role in connecting the generation and storage of renewable energy.

Why is Stopping SF₆ Leaks So Important?

Despite its utility, SF₆ is incredibly detrimental to the planet. With a warming potential that is a staggering 23,500 times higher than carbon dioxide (CO₂)^[1], SF₆ is the most potent greenhouse gas. This means that even in minute quantities, SF₆ has a disproportionately significant impact on global warming. Worryingly, the Environmental Protection Agency notes that leak detection surveys show approximately 10 percent of circuit breaker populations leak and, 85% of these leaks are releasing enough of this dangerous gas to be considered significant. Frequent leaks of such a potent greenhouse gas have become a serious contributing factor to global warming.

Commenting on Belzona's new solution for SF₆ leakage, one of the main developers, Training Facilitator, Karl Rodman, said:

“By implementing this solution, the amount of harmful SF₆ being released into the atmosphere will be significantly reduced. Belzona has created a necessary solution to a prolific problem in this integral industry. Belzona SF6-FIX not only addresses the environmental concerns surrounding SF₆ leakage, but also contributes to the sustainable and efficient functioning of power grids”.

The Online Leak Solution in Action

This electric switch gear flange within a Power Distribution Substation was leaking 70kg of SF₆ per month. In addition to being devastating for the environment, such leaks incur substantial costs, as local authorities can issue hefty fines. Leveraging a strategic combination of expertly applied specialist materials, including reinforcement sheets alongside Belzona's advanced resin and coatings, Belzona successfully stemmed the leak in just one day, without the need to degas the system.

Electric Switch Gear Flange with SF₆ Leak                       SF₆ Leakage Sealed with Belzona SF6-FIX

Six months into service, the solution was deemed successful. The leak has been reduced to an undetectable level, resulting in a monumental environmental and financial saving. This triumphant application has paved the way for the solution's expansion to other substations, offering a practical and efficient means to propel the global power distribution industry towards a more sustainable future.

^[1]

Belzona SF6-FIX Leak Solution Launch

According to the Intergovernmental Panel on Climate Change’s (IPCC) ﷟HYPERLINK "https://www.ipcc.ch/assessment-report/ar5/"fifth assessment report.