The safety and integrity of a flameproof installation are determined the moment it’s installed. Even the highest quality, most rigorously certified piece of equipment can be rendered unsafe by a single installation error. For electrical contractors and in-house electricians, understanding and avoiding these common pitfalls is not just a matter of best practice; it’s a critical safety responsibility.
Based on field audits and incident reports, here are the top five most common and dangerous flameproof installation mistakes, and how to ensure you get them right every time.
This is arguably the most common point of failure. The cable gland is what seals the enclosure around the cable, and if it’s not perfect, it creates a direct path for flammable gas to enter or an internal blast to escape.
The Error: Using a gland that doesn’t match the cable diameter, failing to use a certified stopping plug for an unused entry, or using an IP washer incorrectly.
The Fix: Always use a certified cable gland that is specifically sized for the outer diameter of your cable. Every single unused entry must be sealed with a correctly threaded, certified stopping plug. No exceptions. Verify the thread type (NPT vs. Metric) matches the enclosure entry.
The flame path through the precisely machined gap between the enclosure body and its cover is the heart of protection. Damaging this surface is like punching a hole in a dam.
The Error: Using a screwdriver or other tool to pry open a tight cover, scoring the machined flange surface. Also, applying paint or a thick, non-specified grease over the flame path can seal it and prevent it from “breathing” correctly.
The Fix: Never use a tool to force open an enclosure. If a cover is stuck, investigate the cause (e.g., damaged threads). Keep flame path surfaces meticulously clean and protected during installation. Only apply a thin film of a manufacturer-approved, non-setting grease if specified.
The bolts holding the enclosure cover on are not standard hardware; they are a critical part of the pressure-containing system.
The Error: Replacing a lost or damaged certified, high-tensile steel bolt with a standard, lower-grade bolt from a local hardware store.
The Fix: Treat the bolts as an integral part of the certified assembly. If a bolt is lost or damaged, replace it only with an identical, manufacturer-supplied fastener. Ensure all bolts are present and tightened to the correct torque in a star pattern to ensure even pressure on the cover.
A flameproof enclosure needs space to work. If an internal ignition occurs, hot gases will vent from the flame paths. If this vent is obstructed, the hot gas may not cool sufficiently before reaching the surrounding atmosphere.
The Error: Installing an enclosure too close to a wall, steel beam, or another piece of equipment.
The Fix: Adhere to the minimum clearance distances specified by the standards. These are based on the gas group:
Group IIA: 10mm clearance
Group IIB: 30mm clearance
Group IIC: 40mm clearance
A proper earth connection is essential for preventing the buildup of static electricity, which can be a potent ignition source in a hazardous area.
The Error: A loose, corroded, or improperly sized earthing connection.
The Fix: Ensure all internal and external earth connections are clean, tight, and secure. Verify that the earthing conductor is appropriately sized according to local electrical codes. This is a fundamental step that should never be overlooked.
Proper installation is the final, critical link in the safety chain. By avoiding these common mistakes, you ensure that the equipment performs as designed and certified, protecting the facility and its personnel.
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