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A range of modular, explosion-proof enclosures for electrical equipment, from COOPER Crouse-Hinds, is not only innovatively designed, but can also be tailored to suit the exact requirements of the application - whether for an onshore oil refinery, offshore oil platform or in a harsh industrial environment such as a chemicals plant.
The GHG 64 Ex-d enclosure series, as it is known, represents a leap forward in terms of enclosure design, modularity and application flexibility. Due to optimum material selection, including a high quality powder coating (>100 mm) and the use of stainless steel fixings, the GHG 64 is a compact, flameproof, copper-free aluminum enclosure with a wide temperature range from -20 deg C to + 40 deg C (-55 deg C to +55 deg C option also available).
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11 different sizes of enclosure are available, from W210 x L210 x D191mm, up to W650 x L650 x D442mm. These can be installed in hazardous gas (Ex-d IIB or optional Ex-d IIB + H2) or hazardous dust areas (tD). Rated voltage is up to 690V and rated current is up to 1150A.
The GHG 64 can be interconnected using flameproof bushings, which enables large, complex customized solutions to be assembled. COOPER Crouse-Hinds can also provide a wide variety of integrated control systems and devices, such as contactors, MCBs, RCDs, PLCs, WLAN, time elements, electronic components and terminals - all housed within a space-saving, fully-assembled, fully protected Ex-d enclosure.
The customer can also choose from a variety of optional fittings, including a display window, frameworks for wall and floor mounting, a special hinged cover with up to 110-degree opening angle, as well as a selection of cable entry systems (Ex-d and Ex-e from CEAG and Capri).
Intelligent Hinge Technique
Even if the customer needs to mount the enclosures directly adjacent to one another, special stainless steel hinges can be fitted to the units by COOPER Crouse-Hinds, which enable the enclosure door to be pulled out and swung open at an angle of up to 110 degrees. Once the captive screws are removed, the enclosure cover can be swung open easily due to spring-mounted pull/turn hinges. The flat flamepath is also protected against damage.
As Daniel Eichert, Global Product Line Manager Switchgear at COOPER Crouse-Hinds states: "This innovation not only saves installation space, but also simplifies maintenance work and speeds up the repair and replacement of built-in components."
Cost saving windows
An optional display window can be embedded in the enclosure housing, enabling the user to monitor the display and switch states of built-in components. This eliminates the cost of sourcing additional, explosion-protected indicators for the enclosure.
Sealing system for low maintenance, flat flame paths
The GHG 64 is protected to IP65. However, this can be upgraded to IP66 by fitting an optional lip seal made from a highly heat-resistant, weather-resistant silicone. This gasket system also prevents the ingress of aggressive particles and other foreign matter into the Ex-d flame path, providing long-term corrosion protection and improved safety. In addition, using the IP66 version of the GHG 64 enclosure system results in prolonged maintenance intervals.
Enclosures with lip seals can therefore be installed in extreme environments where moisture, salt water, chemicals and dust are present. This includes offshore oil & gas platforms, marine applications, harsh industrial conditions, and dusty environments such as flour, sugar and saw mills.
High heat dissipation
The high heat dissipation rating of the GHG 64 enclosure means a high degree of flexibility for the customer in terms of which standard industrial components can be safely housed within the Ex-d enclosure. The permissible limiting temperature values are therefore higher with the GHG 64, which saves installation space and provides more flexibility during the planning stage.
Connection and busbar boxes
COOPER Crouse-Hinds has also adapted its Ex-e connection and busbar boxes to suit the new modular GHG 64 enclosures. This means a wide range of electrical distribution connections are possible with currents of up to 1150A.
Busbar boxes are available in Ex-e and Ex-d designs. Rugged Ex-e enclosures made from powder-coated sheet steel or stainless steel can be adapted to the modular system. Ex-d enclosures are made from die cast aluminum alloy. Busbar rails can be used to connect multiple enclosures.
Cover-mounted components
As well as busbar connections and boxes, COOPER Crouse-Hinds can also supply a wide range of cover-mounted components direct from the factory. Threaded Ex-d holes can be incorporated into the GHG 64 cover in order to accommodate a variety of screw-in components such as rotary switches, pushbuttons, nameplates, padlocking mechanisms, signal lamps, windows and actuators for circuit breakers (MCBs).
Intelligent instrumentation for hazardous areas
The modular concept of the GHG 64 series means that the customer can combine the reliable safety of an explosion-protected enclosure with the benefits of a continuous communications infrastructure between the main, control and process levels of a plant. For example, Ethernet-based communications systems can be installed in hazardous areas.
In the process industries, wireless communications are also growing in popularity. By working closely with sister company MTL, COOPER Crouse-Hinds is able to provide customers with complete wireless communications solutions for hazardous areas, including wireless gateways for Profibus, Modbus, RS232 and 485.
Application Examples
GHG 64 Ex-d and Ex-e enclosures have already been implemented in several customer applications. For example, a unique, custom engineered, Ex-Wireless LAN system was developed for an oil and gas customer based in Germany. This system records vibrations from machines in hazardous areas via wireless LAN. Wireless vibration sensors monitor the critical points on the machines directly and measurement data is then transmitted via wireless LAN connection to a computer located in a GHG 64 enclosure. The system can also monitor machines on a permanent basis in order that maintenance activities can be scheduled in time.
In another application, a series of GHG 64 electrical power distribution panels have been delivered to an offshore gas exploration field in the Gulf of Thailand.
For further information, view website: www.ceag.de or e-mail: Gordon.Low@CooperIndustries.com Refer to page 166
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To address the increasing use of ESPE in modern machines, where it often takes the place of traditional guarding, the Health and Safety Executive (HSE) published HSG180, Application of electro-sensitive equipment using light curtains and light beam devices to machinery. This publication is provided for guidance only but, because of the safety critical nature of the use of ESPE, employers are well advised to follow its provisions unless they can demonstrate very good reasons for doing otherwise.
The section of HSG180 that deals with inspection and test states in paragraph 118 that, "installations using ESPE should be inspected at suitable intervals". In paragraph 124, it goes on to explain that the recommended maximum interval between each periodic inspection and test is six months for type 4 ESPE and twelve months for type 2 ESPE, and that this interval will also depend on the equipment it is fitted to and the risk as a whole.
In other words, there are multiple factors that determine how often ESPE should be inspected and tested but, in many cases, this will be more often than routine PUWER assessments are carried out on the machine.
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It is these cases that create a potential pitfall for employers who are not fully aware of the requirements relating to ESPE, as it is now easy to see that simply carrying out regularly scheduled PUWER assessments is not enough - the ESPE will require additional inspection and testing. It is also important to note that, as with PUWER assessments, the inspection and testing of ESPE must be carried out by a person with appropriate competence.
Since many companies have neither the in-house expertise nor the capacity to deal with these additional ESPE inspections, Safety Systems Technology has introduced a new standalone ESPE periodic inspection and test service that can be tailored to suit the requirements of individual sites.
This service accurately follows the guidance given in HSG180 and includes inspection of the ESPE to that ensure that it is the correct distance from the danger zone, ensuring that safeguards are in place to prevent access to the danger zone from directions not covered by the ESPE, testing the response time and detection capability of the ESPE installation, inspecting any stopping performance monitor that may be fitted, and testing primary machine control elements to ensure correct functioning.
Safety Systems Technology Ltd in profile
A division of TÜV SÜD Product Services Ltd and part of the TÜV SÜD group, Safety Systems Technology Ltd is a specialist machinery safety design and installation company that offers customers a complete machine safety solution with cost effective engineering project management designed to suit all machinery safety requirements. It has the knowledge and experience to design and install the most appropriate solutions using products from its wide portfolio from leading manufacturers.
Safety Systems Technology Ltd can provide a range of engineering services, from design studies through to full turnkey projects, and as an independent company, it is not tied to any single safety product vendor, enabling it to design and install a best of breed solution.
For further information, view website: http://www.safetysys.co.uk/
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