Electronic Design for Hazardous Area
Electronic Design for Hazardous Area: Safety & Compliance Solutions
Every device or circuit intended for hazardous area applications must comply with international safety standards to ensure safety. To meet these standards, every element of the circuit, especially those capable of storing energy, must be carefully considered and reviewed. This ensures that the energy cannot ignite any explosive gases present, according to the specific type of hazardous area environment.
Arshon Technology specializes in circuit design that adheres to these stringent hazardous area requirements. We have extensive experience in creating electronics, enclosures, accessories, batteries, barriers, and power supplies for hazardous areas and intrinsically safe applications. With a deep understanding of class and zone definitions and compliance with ATEX requirements, we offer customized solutions to meet the rigorous safety standards of hazardous environments. On this page, we will showcase our expertise in circuit design that meets hazardous area agency reviews and our capabilities in designing barriers and power supplies for safe zone applications.
Understanding Hazardous Areas
Hazardous areas are environments where the presence of flammable gases, vapors, dust, or combustible fibers poses a risk of ignition and explosion. Regulatory bodies classify hazardous areas into zones based on the likelihood and duration of the presence of hazardous substances. Conversely, safe zones are areas where the risk of ignition and explosion is minimal.
Our Expertise in Electronics Design
At Arshon Technology, we specialize in designing electronics tailored for both hazardous areas and intrinsically safe applications. Our team of experienced engineers possesses in-depth knowledge of hazardous area classifications and regulatory requirements, allowing us to develop solutions that meet the highest standards of safety and reliability. We also consult special Hazardous area needs with Hazcon which is an advanced consulting firm in this area.
Circuit Design for Hazardous Areas
Our core competency lies in circuit design that passes hazardous area agency reviews. We understand the critical importance of ensuring that electronic devices deployed in hazardous environments are intrinsically safe and compliant with relevant regulations. Our design process involves rigorous analysis, simulation, and testing to verify the integrity and reliability of the circuits under various operating conditions.
Compliance with ATEX Requirements
ATEX (ATmosphères EXplosibles) is the European regulatory framework governing the manufacture and use of equipment intended for use in explosive atmospheres. Our products are designed and tested in accordance with ATEX directives to ensure compliance with the highest safety standards. From component selection to assembly techniques, we adhere to ATEX requirements at every stage of the design and manufacturing process.
Custom Enclosures, Accessories, and Barriers
In addition to electronics design, we offer custom enclosure solutions tailored to the specific requirements of hazardous area environments. Our enclosure designs comply with hazardous area requirements as well as normal environmental parameters such as moisture, dust, and corrosion, while ensuring adequate ventilation and heat dissipation. We also offer a range of customer accessories, including cable connection, barrier between environments as well as Intrinsically Safe design by means of encapsulation or by means of design elements itself.
Moreover, we specialize in barrier design for hazardous area applications, providing intrinsically safe barriers that limit electrical energy and prevent ignition sources in hazardous environments. Our barriers are designed to provide reliable protection for sensitive equipment and personnel operating in hazardous areas.
Power Supply Solutions for Intrinsically Safe applications
In safe zone applications, reliable power supplies are essential for powering electrical equipment and ensuring uninterrupted operation. Our power supply solutions are designed to meet the specific requirements of safe zone environments, providing stable and efficient power delivery with minimal risk of electrical hazards. Whether you need AC or DC power supplies, we can provide customized solutions tailored to your application needs.
We offer comprehensive solutions for electronics design, enclosures, accessories, batteries, barriers, and power supplies for both hazardous area and intrinsically safe applications. With our extensive experience and commitment to excellence, you can trust us to deliver reliable, intrinsically safe products tailored to your specific needs. Contact us today to learn more about our capabilities and how we can support your projects.
Hazardous Area Design
Hazardous areas require specialized engineering strategies to mitigate the risk of ignition and explosion, making hazardous area design and engineering a critical focus for industries like oil and gas, chemical processing, and mining. These environments often contain flammable gases, dust, or vapors, all of which can spark catastrophic incidents if not properly managed. Through a meticulous approach that balances safety, functionality, and regulatory compliance, companies can confidently design for explosive environments while maintaining operational efficiency. This involves careful selection of electronic components, rigorous testing under worst-case scenarios, and the integration of redundant safety measures such as current-limiting circuits and robust enclosures. Engineers must also ensure that any heat generated by components remains below ignition thresholds and that potential fault conditions are systematically addressed in both hardware and firmware. Equally important is compliance with global standards such as ATEX, IECEx, and NEC, which demand in-depth documentation, third-party testing, and clear procedures for maintenance and repair. By prioritizing a holistic design approach—incorporating everything from power management to grounding and shielding—organizations can create solutions that not only meet strict safety requirements but also deliver reliable performance in harsh settings. Ultimately, effective hazardous area design safeguards both personnel and infrastructure, enabling advanced technologies to thrive even in the most challenging industrial environments.
Hazardous Area Solutions
Implementing robust hazardous area solutions is essential for ensuring the safety and efficiency of operations in industries where flammable gases, dust, or liquids may be present—such as oil refineries, chemical plants, and mining facilities. These specialized designs involve the careful selection of components, enclosures, and circuit layouts that minimize the risk of spark or heat generation, both of which could ignite volatile substances. Beyond basic compliance, forward-thinking designs also incorporate fault tolerance and fail-safe mechanisms that maintain productivity while safeguarding personnel. A key component of these systems includes hazardous area workstations, which enable operators to monitor and control processes in real time without compromising safety. These workstations often feature explosion-proof enclosures, intrinsically safe input devices, and integrated power management solutions that limit electrical and thermal energy output. Investing in comprehensive hazardous area solutions allows organizations to leverage cutting-edge technology, from advanced process control algorithms to data analytics, even in the most challenging environments. By harmonizing protective measures with modern industrial practices, companies can enhance operational integrity, reduce downtime due to safety concerns, and maintain a competitive edge in today’s increasingly complex market landscape.
Hazardous Location Power Supply
Designing a hazardous location power supply requires careful planning to ensure compliance with safety regulations while delivering reliable performance in explosive environments. These specialized power solutions must adhere to hazardous location product safety standards such as ATEX, IECEx, and UL, which define strict limits on electrical energy to prevent ignition risks. Through intrinsically safe design consultancy, engineers develop power systems that control voltage, current, and thermal dissipation, ensuring that every component operates within safe parameters. This process includes selecting intrinsically safe or explosion-proof components, implementing current-limiting circuits, and designing redundant safety mechanisms to enhance reliability. Additionally, certified intrinsically safe design services help companies achieve compliance by conducting risk assessments, validation testing, and regulatory documentation. Proper hazardous area design and planning is essential for integrating power supplies into larger systems, ensuring that all interconnected devices function safely in volatile conditions. From powering industrial sensors and communication equipment to supporting mission-critical automation systems, an intrinsically safe power supply is a fundamental component of hazardous location operations. By partnering with experienced design specialists, businesses can ensure their power solutions meet both safety and performance requirements, allowing them to operate confidently in environments where electrical safety is paramount.
FAQ (Frequently Asked Questions)
1) What are the requirements for a hazardous area?
A hazardous area is defined as an environment where flammable gases, vapors, dust, or fibers may be present in sufficient concentrations to create an explosion or fire risk. The key requirements for hazardous areas include proper hazardous area classification, selection of certified explosion-proof or intrinsically safe equipment, strict adherence to NEC (National Electrical Code) and IEC (International Electrotechnical Commission) standards, and ongoing maintenance and inspections to ensure safety compliance. At Arshon Technology, we specialize in designing and developing electronic systems for hazardous areas that meet these stringent requirements and ensure safe operation in challenging environments.
2) What are the hazardous area classifications for the NEC?
The NEC (National Electrical Code) classifies hazardous areas into Classes, Divisions, and Groups under Article 500.
Class I: Areas with flammable gases or vapors (e.g., petrochemical plants).
Class II: Areas with combustible dust (e.g., grain elevators).
Class III: Areas with ignitable fibers or flyings (e.g., textile mills).
Each Class is divided into:
Division 1: Hazard is present during normal operations.
Division 2: Hazard is present only under abnormal conditions.
Arshon Technology provides electronic designs that meet NEC hazardous area classifications, ensuring certified intrinsically safe solutions for Class I, II, and III locations.
3) Does Class II Div 2 require explosion-proof?
Class II, Division 2 areas may not always require explosion-proof equipment, but devices installed in these areas must be rated and certified for the specific hazardous conditions. In many cases, dust-ignition-proof or intrinsically safe equipment is used instead of explosion-proof enclosures, depending on the risk assessment. Arshon Technology offers hazardous area design services, developing intrinsically safe electronic systems that comply with Class II, Div 2 requirements and minimize ignition risks.
4) What is the difference between NEC 500 and NEC 505?
The difference between NEC 500 and NEC 505 lies in how they classify hazardous areas and equipment protection concepts.
NEC 500 uses the Class/Division system.
NEC 505 aligns with international Zone classifications, similar to IEC standards:
Zone 0: Continuous presence of hazardous gases.
Zone 1: Intermittent presence.
Zone 2: Unlikely presence, but still possible.
NEC 505 encourages equipment standardization with international regulations. Arshon Technology designs electronic products that comply with both NEC 500 and NEC 505, ensuring global market access and safety.
5) What is the IEC standard for hazardous areas?
The IEC 60079 series is the international standard for equipment used in hazardous areas. This includes guidelines for equipment protection by intrinsic safety (Ex i), flameproof enclosures (Ex d), increased safety (Ex e), and pressurization (Ex p). IEC standards classify hazardous areas into Zones (0, 1, 2 for gases and 20, 21, 22 for dusts) based on the likelihood of an explosive atmosphere. At Arshon Technology, we design and develop intrinsically safe electronic systems that meet IEC 60079 standards, ensuring global compliance and safe operation in hazardous environments.
6) How do you classify a hazardous area?
Classifying a hazardous area involves assessing the types of flammable materials present (gases, vapors, dusts), their concentration, and the likelihood of their presence. The classification determines whether the area falls under NEC Classes/Divisions or IEC Zones.
Key steps include:
- Identify the hazardous substances.
- Evaluate the potential for an explosive atmosphere.
- Determine frequency and duration of exposure.
- Assign Class/Division or Zone ratings.
Arshon Technology works closely with clients to develop hazardous area design and engineering solutions that conform to appropriate classifications, ensuring compliance with both NEC and IEC regulations.
