Explosion protection without illusions: not the parts, but the system

Ex-marking isn't a magical seal of safety, but just one element of a complex system. We explore why explosion-proof equipment only works when properly designed, carefully selected, installed correctly, and maintained—and where even experienced professionals most often make mistakes.

At GORELTEX , we often encounter the perception that explosion-proof equipment simply consists of enclosures and Ex markings. In reality, explosion-proof equipment is an element of an overall industrial safety system, where an error at any stage—from design to decommissioning—can lead to an emergency.

In our experience, questions and problems arise already at the design stage. The specialist must consider the requirements of the Electrical Installation Code (PUE), GOST (State Standard), SP (Special Regulations), TR CU (Traditional Electrical Installation Code), industry regulations, and internal company standards. However, there is no single, simple, and unambiguous regulatory framework: documents can complement each other, be interpreted differently, or fail to address specific practical issues.

Another cornerstone is equipment selection. At this stage, suppliers face a whole host of questions regarding equipment specifications: markings and explosion protection principles, temperature classes and hazardous areas, as well as materials, shock resistance levels, dust and moisture protection, vibration protection, and many other parameters that determine the plant's explosion protection.

The installation stage is no less important. Common mistakes include incorrectly selected cable glands, damaged seals, non-compliance with grounding requirements, damaged enclosures, and equipment installation without regard for the zone, gas group, or temperature class. It's important to remember that even high-quality, certified equipment loses its protective properties if improperly installed.

During operation, problems often arise from a lack of inspection plans and a perfunctory approach to inspections and maintenance. Equipment operates in harsh conditions, including vibration, corrosion, temperature fluctuations, and aggressive environments. Loose fasteners, loss of sealing, improper replacement of components, or the use of unsuitable spare parts can render explosion protection effectively inoperable.

Safety at industrial facilities in hazardous areas is ensured not by a single product, but by a system of solutions: sound design, high-quality equipment, proper installation, regular maintenance, and the professional responsibility of specialists. Every year, the requirements for the qualifications and expertise of industry specialists are becoming more stringent, and the safety of the entire facility depends on their well-considered and informed decisions.

GORELTEX is the market leader in explosion-proof equipment*. Our equipment is installed at virtually every medium and large industrial facility requiring explosion protection. Over 32 years of operation, we've accumulated valuable practical experience that we're ready to share. We're launching a series of articles for professionals, where we'll address emerging issues and share our best practices, so we can all feel more confident and safer.

See you soon, GORELTEX team!