A Practical Engineering & Compliance-Based Selection Framework for Hazardous Industrial Environments

The Best Choice for Most Zone 1 Plants

For Zone 1 hazardous environments, Flameproof Split AC is the preferred and most widely adopted solution due to better installation flexibility, lower noise, and superior reliability.

Flameproof Window AC is suitable for small enclosures and limited-size rooms in Zone 2.

For deeper context on hazardous classifications, review: A Comprehensive Guide to Zone 0, Zone 1, Zone 2 & Zone 3 – Read the Zone Classification Guide

Side-by-Side Technical & Cost Comparison

Explore certified solution options: Flameproof Split Air Conditioner

Why Industries Are Phasing Out Flameproof Window AC

Although flameproof window ACs were widely used historically, they present limitations:

1. Limited cooling capacity (maximum around 2 TR)
    
2. High vibration noise and single-chassis problems
    
3. Structural wall opening required
    
4. Low serviceability inside hazardous perimeter
    
5. Less effective airflow distribution
    

Refrigerant Safety Matters

Modern split AC systems commonly use R410A and R32 refrigerants.Since R32 is mildly flammable, having a hermetically sealed Ex d compressor in a Flameproof Split AC significantly reduces ignition risk compared to older window AC designs lacking robust containment.

Typical Use Cases for Window AC

Advantages of Flameproof Split AC in Hazardous Areas

Correct Placement of Outdoor Unit: Engineering Scenarios

Scenario A: Outdoor Unit in Safe Area

If a safe (non-hazardous) area is located nearby:

1. Only the indoor evaporator unit requires Ex certification
    
2. Copper pipeline, drain, and control cable routed through sealed penetration
     This option significantly reduces procurement and maintenance cost.
    

Scenario B: Outdoor Unit also in Hazardous Area

If no safe zone is available:

1. Both indoor and outdoor units must be flameproof certified
    
2. Outdoor compressor must be in Ex d certified enclosure
    
3. All cables must be routed using armored cable and double compression Ex d glands
    

This configuration is common in:

1. Tank farms
    
2. Petrochemical units
    
3. LPG / CNG handling facilities
    
4. Refining & blending units
    

Zone 1 vs Zone 2 AC Selection

Learn more about flameproof safety:

1. What Is Flameproof Equipment?
2. Difference Between Explosion-Proof & Flameproof

Decision Matrix

Industry Case Study

A pharmaceutical manufacturing unit in Maharashtra replaced two FLP Window ACs due to repeated breakdowns and noise interference affecting PLC monitoring.
  Switching to 1.5 TR Flameproof Split AC installed with outdoor unit in Safe Zone achieved:

1. Cooling response time improvement by 28 percent
    
2. Zero vibration issues
    
3. Audit-compliant documentation for PESO inspection
    

Frequently Asked Questions

Can I use a standard split AC with explosion-proof add-ons?
  No. Retrofitted or sensor conversions are not certified and violate PESO guidance.

Can a window AC be used in Zone 1?
  Not recommended. Only in Zone 2 if certified.

Do flameproof split ACs require special cabling?
  Yes. Must use armored cables with Ex d glands and certified sealing systems.

Conclusion

Choosing the correct HVAC system for hazardous industrial environments is a high-impact engineering decision.
 
 For most Zone 1 facilities, Flameproof Split AC delivers the best combination of safety, flexibility, efficiency, and compliance.
 
 Window AC serves limited small-room use cases in Zone 2, while Pressurized HVAC is unmatched for large or mission-critical environments.

Explore industrial-grade HVAC solutions built for hazardous applications: Flameproof Split Air Conditioner — Explore Solutions