Customized Explosion-Proof Single-Head Heating Element: Safety Design Standards for Hazardous Environments

Kev tawg- pov thawj ib leeg- cov khoom cua sov kawg yog cov khoom cua sov hauv cov chaw muaj kev phom sij xws li cov nroj tsuag tshuaj, cov nroj tsuag roj av, mines, thiab offshore platforms. Lawv cov kev tsim kho tau ncaj qha cuam tshuam rau kev nyab xeeb thiab khoom siv ruaj khov. Cov chaw muaj kev phom sij muaj cov pa taws thiab tawg, vapors, lossis plua plav. Yog tias cov khoom cua sov tsis tuaj yeem tiv thaiv kev tawg, raug kev puas tsuaj los ntawm rwb thaiv tsev, los yog muaj kev kub ntxhov, nws tuaj yeem ua rau tawg, hluav taws kub, thiab lwm yam xwm txheej loj. Kab lus no, sib txuas cov kev coj ua hauv kev lag luam thiab cov kev qhia tshwj xeeb, qhia meej txog cov qauv kev nyab xeeb ntawm cov qauv tsim rau kev ua kom tawg tau zoo - pov thawj ib zaug - cov khoom cua sov, muab cov txheej txheem rau lawv daim ntawv thov nyob rau hauv ib puag ncig txaus ntshai.

I. Basic Explosion-Cov ntaub ntawv pov thawj kev sib raug zoo

Kev tawg- pov thawj ntsuas yog qhov yuav tsum tau ua ua ntej rau kev hloov pauv kev tawg- pov thawj ib zaug - xaus cov cua sov. Nws yuav tsum tau ua raws nraim raws li qhov kev faib tawm tsam tsam tawg, hom nruab nrab, thiab pab pawg kub ntawm qhov chaw muaj kev phom sij kom ntseeg tau tias qhov tawg tau ruaj khov- pov thawj kev ua tau zoo hauv ib puag ncig.

1.1 Kev hloov kho rau thaj chaw muaj phom sij tawg

Raws li GB 3836 series cov qauv thiab thoob ntiaj teb IEC 60079 cov qauv, thiab txiav txim siab qhov chaw tawg phom sij ntawm daim ntawv thov scenario (Zones 0, 1, thiab 2 yog ib puag ncig gaseous; Zones 20, 21, thiab 22 yog plua plav ib puag ncig), cov nram qab no customization yog muab:

- Siab-frequency hazardous area (Zones 1, 21, and above): Intrinsically safe (Ex ia) los yog tawg-cov ntaub ntawv pov thawj (Ex d) cov qauv yuav tsum tau saws los xyuas kom meej tias cov cua kub tsis tsim cov txim taws lossis kub kub uas tuaj yeem cuam tshuam cov khoom tawg tawg; nyob rau hauv ib txwm ua haujlwm thiab faults

- Tsawg- thaj chaw muaj kev phom sij (Zones 2 thiab 22): Kev nyab xeeb ntxiv (Ex e) lossis tawg- cov qauv pov thawj tuaj yeem xaiv tau, nrog rau kev tsom mus rau kev tswj qhov kub thiab txias ntawm cov cua sov thiab kev tshem tawm hluav taws xob.

1.2 Kev sib piv ntawm Media Hom thiab tawg -Cov pov thawj ntsuas

Kev tawg- pov thawj kev ntsuas yog txiav txim siab raws li qhov teeb meem ntawm qhov teeb meem ntawm cov nplaim taws thiab tawg hauv ib puag ncig. Cov qauv tsim kev cai yuav tsum ua kom tau raws li qhov yuav tsum tau muaj ntawm cov kev ntsuas sib xws:

- IIB- theem xov xwm (piv txwv li, ethylene, acetone): Cov pa tawg- cov qauv pov thawj txaus, nrog rau qhov tawg- pov thawj ntsuas tsis qis dua Exd IIB;

- IIC-theem siab- cov xov xwm txaus ntshai (piv txwv li, hydrogen, acetylene): Kev siv hluav taws xob tawg ntxiv- cov qauv pov thawj yuav tsum muaj, nrog rau kev tawg- pov thawj qhov ntsuas tau ncav cuag Exd IIC kom ntseeg tau tias tiv taus siab dua - hluav taws xob tawg cuam tshuam thiab tiv thaiv tawg-cov ntaub ntawv pov thawj los ntawm rupturing;

- Plua plav ib puag ncig (xws li, txhuas hmoov, thee hmoov): Plua plav tawg- cov ntaub ntawv pov thawj (Ex tD) yuav tsum tau xaiv, nrog rau kev tsom mus rau kev ua kom zoo ntawm cov ntaub thaiv npog thiab kev tiv thaiv plua plav.

1.3 Precise Temperature Group Control

Cov pab pawg kub yuav tsum tau txiav txim siab raws li qhov siab tshaj plaws ignition kub ntawm qhov nruab nrab. Qhov kub ntawm qhov cua sov thaum lub sijhawm ua haujlwm ib txwm yuav tsum yog tsawg kawg 10℃qis dua qhov kub ntawm qhov nruab nrab. Cov pab pawg kub sib raug zoo yuav tsum tau qhia meej meej thaum lub sijhawm kho:

- T4 Pawg (qhov siab tshaj plaws ntawm qhov kub thiab txias tsawg dua lossis sib npaug ntawm 135 degree): Haum rau feem ntau cov tshuaj (xws li roj av, methanol);

- T6 Pawg (qhov siab tshaj plaws saum npoo qhov kub tsawg dua lossis sib npaug li 85 degree): Haum rau siab - kub, yooj yim ignited media (piv txwv li, hydrogen, acetylene). Deg load yuav tsum tau txo los ntawm cov qauv optimization los tswj tus nqi ntawm kub nce.

II. Cov qauv kev nyab xeeb rau kev xaiv cov khoom tseem ceeb

Cov khoom siv ncaj qha txiav txim siab qhov siab -kub tsis kam, tiv thaiv corrosion, rwb thaiv tsev, thiab tawg- pov thawj kev ruaj ntseg ntawm qhov tawg- pov thawj ib zaug - tas cov cua sov. Kev xaiv meej yuav tsum yog raws li cov yam ntxwv ntawm qhov nruab nrab, kev ua haujlwm kub, thiab ib puag ncig.

2.1 Cov ntaub ntawv vaj tsev thiab cov ntaub qhwv

Lub vaj tse thiab sheath yuav tsum ua kom tau raws li qhov yuav tsum tau ua kom tawg - pov thawj, corrosion resistance, thiab mechanical zog:

- Ib puag ncig corrosive: 304 stainless hlau, kub tsis kam Tsawg dua los yog sib npaug li 600 degree, haum rau dej, nruab nrab cov kev daws teeb meem, thiab cov xov xwm me me;

- Muaj zog corrosive ib puag ncig (xws li, hydrochloric acid, sodium hydroxide, dej hiav txwv): 316L stainless hlau los yog titanium, 316L kub tsis kam Tsawg dua los yog sib npaug rau 800 degree, titanium kub kuj tsawg dua los yog sib npaug li 500 degree, zoo tiv taus acid, alkali, thiab chloride;

- High-temperature conditions (operating temperature >800℃): Incoloy 800/840 los yog lwm yam siab -nickel alloys, muaj zoo heev -kub oxidation kuj thiab creep zog, tiv thaiv cov khoom deformation los yog tawg ntawm qhov kub thiab txias.

2.2 Cov khoom siv cua sov thiab cov khoom siv rwb thaiv tsev

Cov khoom siv cua sov thiab cov khoom siv rwb thaiv tsev yuav tsum xyuas kom muaj kev hloov pauv ntawm electrothermal thiab hluav taws xob rwb thaiv tsev kev ntseeg tau:

- Cov Cuab Yeej Cuab Yeej: Cr20Ni80 npib tsib xee- chromium alloy raug xaiv, nrog kev tiv thaiv ruaj khov (1.09 ± 0.05μΩ·m). Ntev-lub sij hawm ua haujlwm kub tuaj yeem ncav cuag 1100 degree, txuas lub neej ntev li 3 npaug piv rau hlau-chromium- aluminium alloys. Rau siab-cov qauv tsim hluav taws xob, lub tshuab cua sov txoj kab uas hla yuav tsum tau ua kom zoo (pom zoo dua los yog sib npaug li 12 hli) kom txo tau qhov chaw load thiab tsis txhob overheating hauv zos.

- Rwb thaiv tsev Filler: High- ntom crystalline magnesium oxide hmoov (MgO) yog siv, nrog cov thermal conductivity Ntau dua los yog sib npaug rau 0.035W/(m·K), kom ntseeg tau tias muaj kev hloov hluav taws xob zoo thiab kev ua haujlwm zoo ntawm hluav taws xob rwb thaiv tsev. Qhov muab tub lim yuav tsum muaj ntau dua lossis sib npaug li 2.7g / cm³ kom tsis muaj qhov khoob thiab tsis muaj kev daws teeb meem, tiv thaiv kev puas tsuaj.

2.3 Cov khoom siv sib khi thiab xaim

Sealing cov ntaub ntawv yuav tsum tiv thaiv cov xov xwm corrosion thiab xyuas kom tawg - pov thawj sealing kev ua tau zoo. Cov khoom siv hluav taws xob yuav tsum ua kom tau raws li qhov yuav tsum tau muaj kev nyab xeeb hluav taws xob:

- Cov ntsaws ruaj ruaj: Silicone roj hmab lossis fluororubber sealing nplhaib yog siv. Silicone roj hmab yog kub resistant ntawm -60℃mus rau 250℃thiab yog haum rau ib txwm ua hauj lwm tej yam kev mob; fluororubber yog kub resistant los ntawm -20℃mus rau 280℃thiab yog haum rau heev corrosive thiab high-temperature kev khiav hauj lwm tej yam kev mob. Lub sealing compression yuav tsum tau tswj tsis pub dhau 30% mus rau 50% kom ntseeg tau tias IP65 lossis siab dua tiv thaiv ntsuas.

- Terminals: tooj liab- plated nyiaj yog siv, muab cov conductivity zoo heev thiab muaj zog oxidation tsis kam. Cov thawv sib txuas yog ua los ntawm cov cam khwb cia txhuas nrog lub zog muaj zog Ntau dua lossis sib npaug li 50J / m². Kev tawg-cov pov thawj kab noj hniav yuav tsum tau muab rau sab hauv kom tiv thaiv kom tsis txhob muaj hluav taws xob ntawm cov xaim hluav taws xob.

III. Cov qauv tsim kev nyab xeeb Specifications

Tus qauv tsim yuav tsum tsom mus rau peb yam tseem ceeb: tawg- pov thawj sealing, tswj qhov kub thiab txias, thiab kev tiv thaiv txhua yam, kom tsis txhob tawg- pov thawj tsis ua hauj lwm lossis kev nyab xeeb vim muaj kev cuam tshuam ntawm cov qauv.

3.1 Explosion-proof Sealing Structure Design

Ib qho triple-kev tiv thaiv sealing qauv tau txais los ua kom ntseeg tau tias cov khoom siv hluav taws xob thiab cov khoom tawg tsis cuam tshuam rau hauv lub tshuab cua sov thiab lub thawv sib txuas:

- Thawj lub foob: Lub tshuab cua sov qhov chaw nres nkoj siv lub hau kawg ceramic rau rwb thaiv tsev sealing los tiv thaiv magnesium oxide hmoov kom tsis txhob damp thiab tawm mus;

- Lub foob thib ob: Kev sib txuas ntawm lub plhaub thiab lub thawv sib txuas siv lub foob welded + sealing nplhaib rau kev tiv thaiv ob. Lub weld seam yuav tsum tau kuaj rau huab cua nruj, nrog tus nqi xau tsawg dua lossis sib npaug li 1 × 10⁻⁶ Pa·m³ / s;

- Lub foob thib peb: Lub thawv ntawv sib txuas siv qhov tawg tawm - pov thawj lub caj pas foob, sib xws nrog cov kab sib txawv ntawm cov kab sib txawv, thiab raug kaw kom ruaj ntseg yam tsis tau xoob, tiv thaiv plua plav thiab roj nkag mus.

3.2 Kev Tswj Kub Kub thiab Kev Tiv Thaiv Kev Tiv Thaiv Kev Tshaj Tawm

Xav txog qhov kub thiab txias ntawm qhov chaw muaj kev phom sij, kev tswj qhov kub thiab txias thiab kev tiv thaiv overheat yog siv los tiv thaiv qhov kub thiab txias:

- Surface Load Control: Nto load yog teem raws li qhov nruab nrab yam ntxwv: Tsawg dua los yog sib npaug rau 8W / cm² rau cov kua cua sov scenarios thiab Tsawg tshaj los yog sib npaug rau 5W / cm² rau cov xwm txheej cua sov, tiv thaiv lub zos overheating uas yuav ua rau nruab nrab decomposition los yog ignition;

- Ua-nyob rau hauv Kub Sensor: A PT100 platinum kuj kub sensor yog embedded nyob ze ntawm lub cua sov caij los saib xyuas cov cua kub nyob rau hauv lub sij hawm ntawm lub sij hawm, ua tiav ib tug kub tswj qhov tseeb ntawm ± 1 degree;

- Overheat Protection Device: Ib qho kev ywj pheej overheat tiv thaiv module yog kev koom ua ke. Thaum qhov kub thiab txias tshaj qhov teeb tsa los ntawm 5 degree, lub zog yuav txiav tawm tsis pub dhau 0.5 vib nas this los tiv thaiv cov cua sov los ntawm kev kub hnyiab los yog qhov nruab nrab ntawm overheating thiab carbonizing;

- Txo qhov hluav taws xob pib-up Tsim: Rau cov khoom siv cua sov (xws li nitrates thiab paraffin), yuav tsum muaj qhov txo qis pib- nce module. Qhov hluav taws xob tau nce mus rau qhov ntsuas hluav taws xob tom qab qhov nruab nrab tau yaj tag, tiv thaiv kev kub ntxhov hauv cheeb tsam thaum pib.

3.3 Mechanical Protection thiab Installation Design

Raws li cov yam ntxwv ntawm kev teeb tsa cov cuab yeej siv thiab kev ua haujlwm nyob rau hauv ib puag ncig txaus ntshai, cov qauv siv tshuab ua kom zoo raws li hauv qab no:

- Txhim kho Mechanical Strength: Lub sheath phab ntsa thickness yog teem raws li daim ntawv thov scenario, Ntau tshaj los yog sib npaug rau 1.5mm rau ib txwm ua hauj lwm tej yam kev mob thiab ntau tshaj los yog sib npaug rau 3 hli rau siab - ib puag ncig siab, los tiv thaiv kev puas tsuaj los ntawm kev sib tsoo los yog kev cuam tshuam los ntawm lub siab;

- Adaptable Installation Methods: Flange los yog threaded txuas yog siv. Cov khoom siv flange zoo ib yam nrog lub plhaub. Cov xov sib txuas yuav tsum tau nruab nrog cov khoom siv tiv thaiv- xoob kom ntseeg tau tias lawv tsis xoob raws li kev co. Hauv cov xwm txheej ua kua cua sov, cov cua kub yuav tsum tau muab tso rau hauv qhov nruab nrab, nrog qhov deb ntawm Ntau dua lossis sib npaug li 50 hli los ntawm lub thawv phab ntsa kom tsis txhob muaj cua sov hauv zos;

- Junction Box Protection: Lub thawv sib txuas yuav tsum tau muab tso rau hauv cov txheej txheem rwb thaiv tsev thiab sab nraum lub tshuab cua sov, kom deb ntawm cov khoom siv hluav taws xob thiab cov khoom tawg, kom ntseeg tau tias lub qhov hluav taws xob qhov hluav taws xob tau qhuav thiab huv si kom tsis txhob muaj kev cuam tshuam los yog luv luv.

IV. Hluav taws xob Safety Design Standards

Kev nyab xeeb hluav taws xob yog qhov tseem ceeb rau kev ua haujlwm ruaj khov ntawm kev tawg - pov thawj ib zaug - lub taub hau cua sov. Kev tswj xyuas nruj ntawm kev tshem tawm hluav taws xob, kev nkag mus deb, thiab kev ua haujlwm rwb thaiv tsev yog qhov tsim nyog los tiv thaiv hluav taws xob tsis zoo los ntawm kev ua kom muaj kev nyab xeeb.

4.1 Clearances thiab Creepage nrug

Clearances thiab creepage nrug yuav tsum tau teem raws li qhov ntsuas voltage thiab tawg- pov thawj ntsuas, ua tau raws li qhov yuav tsum tau ntawm GB 3836.1 tus qauv:

- Ntawm qhov ntsuas hluav taws xob ntawm 380V, qhov kev tshem tawm ntawm cov polarities sib txawv yuav tsum siab dua lossis sib npaug li 2.5 hli, thiab qhov kev ncua deb Ntau dua lossis sib npaug li 3.0mm;

- Qhov kev tshem tawm ntawm qhov chaw nyob thiab cov hlau casing yuav tsum siab dua los yog sib npaug li 1.0mm, thiab qhov deb ntawm qhov nkag siab dua los yog sib npaug li 1.0mm;

- Rau IIC-chav foob pob- cov khoom pov thawj, qhov kev ncua deb yuav tsum tau nce ntxiv txhawm rau txhim kho kev ntseeg tau ntawm rwb thaiv tsev.

4.2 Rwb thaiv tsev kev ua tau zoo

Kev ua tau zoo ntawm rwb thaiv tsev yuav tsum dhau qhov kev xeem nyob rau hauv ob qho tib si ib txwm muaj thiab siab - qhov kub thiab txias kom tsis txhob muaj kev pheej hmoo ntawm rwb thaiv tsev tsis ua haujlwm:

- Cov rwb thaiv tsev txias: Ntau dua lossis sib npaug ntawm 200MΩ ntawm qhov kub thiab txias, ntsuas siv 500V megohmmeter;

- Kev rwb thaiv tsev kub: Ntau dua lossis sib npaug ntawm 1MΩ ntawm kev ua haujlwm kub, tiv thaiv kev laus los ntawm kev kub siab;

- Kev ntsuas hluav taws xob: Siv 50Hz, 1000V sinusoidal AC voltage rau 1 feeb, tsis muaj kev puas tsuaj lossis flashover; siv 1250V sinusoidal AC voltage rau 1 feeb nyob rau hauv cov huab cua ntub, tsis muaj kev cuam tshuam ntawm kev ua haujlwm rwb thaiv tsev.

4.3 Kev Siv Hluav Taws Xob Hloov Kho thiab Kev Tsim Kho Hauv av

- Fais fab Parameter Matching: Rated voltage yuam kev Tsawg dua los yog sib npaug rau ± 10%, input fais fab sib txawv tswj nyob rau hauv +5% ~ -10%, zam lub hwj chim txawv txav thiab kub runaway tshwm sim los ntawm voltage fluctuations;

- Kev Xav Tau Kev Ruaj Ntseg: Lub casing yuav tsum tau nruab nrog lub chaw nres tsheb hauv av, nrog rau kev tiv thaiv hauv av tsawg dua lossis sib npaug li 4Ω, ua kom lub sijhawm tam sim no dissipation nyob rau hauv cov ntaub ntawv ntawm to thiab tiv thaiv cov neeg ua haujlwm kev nyab xeeb;

- Kev tswj tam sim no: Cov dej xau tam sim no tsawg dua lossis sib npaug li 0.75mA nyob rau hauv kev ua haujlwm, tiv thaiv cov hluav taws xob ntau dhau los ntawm qhov ua rau hluav taws xob tawg.

V. Customized Testing and Certification Standards

Tom qab tawg - pov thawj ib zaug - lub taub hau cua sov lub taub hau yog hloov kho, nws yuav tsum tau ua nruj me ntsis kev sim thiab ntawv pov thawj kom ua raws li cov qauv tsim kev nyab xeeb ua ntej siv rau hauv qhov chaw muaj kev phom sij.

5.1 Cov khoom kuaj tseem ceeb

- Explosion- pov thawj kev ua tau zoo: Kev ua pov thawj tawg- pov thawj tiv thaiv qhov ntsuas hluav taws xob thiab kev ntsuas hluav taws xob txhawm rau txheeb xyuas qhov ua tau zoo ntawm kev tawg- cov qauv pov thawj;

- Kev ntsuas qhov kub thiab txias: ntsuas qhov kub thiab txias tswj qhov tseeb kom ua tau raws li qhov xav tau ntawm pab pawg kub;

- Kev ntsuas rwb thaiv tsev thiab hluav taws xob muaj zog: ua kom tiav qhov txias thiab kub lub xeev rwb thaiv tsev tiv thaiv thiab kev ntsuas hluav taws xob;

- Kev ntsuas kev ua tau zoo ntawm kev sib khi: Ua qhov ntsuas huab cua lossis ntsuas dej tsis zoo thiab plua plav kom ntseeg tau tias qib kev tiv thaiv ua tau raws li cov qauv;

- Kev ntsuas kev ua tau zoo ntawm cov tshuab: Ua cov kev ntsuas kev vibration thiab cov kev ntsuam xyuas cuam tshuam los xyuas qhov ruaj khov ntawm cov qauv siv tshuab.

5.2 Daim Ntawv Pov Thawj Yuav Tsum Tau

Cov khoom lag luam yuav tsum dhau qhov kev sim ntawm National Explosion-cov ntaub ntawv pov thawj Cov Khoom Siv Hluav Taws Xob Zoo Saib Xyuas thiab Tshawb Xyuas Lub Chaw thiab tau txais qhov tawg- pov thawj daim ntawv pov thawj (Ex certification); Cov khoom xa tawm kuj tseem yuav tsum ua raws li cov qauv ntawv pov thawj thoob ntiaj teb xws li CE thiab UL kom ntseeg tau tias muaj kev sib raug zoo nrog cov cai tswj kev nyab xeeb ntawm lub hom phiaj kev lag luam.