Explosion-Proof Gantry Crane & Overhead Crane for Industrial Hazardous Zones
Explosion-proof cranes and ordinary industrial cranes may look similar in appearance and structure, but the core design, accessory configuration, safety logic and compliance standards are completely different. Choosing the wrong model will not only lead to equipment can not pass the project acceptance, but also leave continuous safety hazards.
This article combines various types of industrial high-risk projects around the world landing experience, a clear comparison of the two types of Crane application scenarios, core differences, selection parameters, pit avoidance points, to help purchasers accurately match the appropriate equipment.
Mainstream application project scenarios of the two types of Cranes
Explosion-proof cranes and ordinary cranes are very clear application boundaries, whether or not there is a source of explosive hazards within the scene, is the core premise of the distinction between the selection of different scenarios of the risk level and equipment fitness standards are significantly different.
Oil and gas facilities
Oil and gas mining and processing plants belong to the first-class high-risk explosion-proof scene, the operation area is always present in the spread of combustible gas leakage risk. Equipment overhaul, pipeline lifting, heavy equipment shifting and other operations, the whole process needs to eliminate any ignition source.
This type of scene is strictly prohibited the use of ordinary Crane, must be equipped with compliant explosion-proof lifting equipment, the whole control of electrical sparks, mechanical friction sparks, suitable for oil and gas mixture of high-risk explosive environment.
Chemical and petrochemical plants
Petrochemical deep processing, fine chemical plant will store, process all kinds of flammable and explosive solvents, process gases and chemical raw materials. Production process volatile vapors, diffuse harmful gases, will make the workshop in a long-term unstable high-risk state.
Tanks, equipment and material lifting operations in the workshop must use chemical-specific explosion-proof Crane to meet the explosion-proof compliance requirements of the hazardous area and avoid safety accidents caused by equipment operation.
Spraying and solvent treatment workshop
Paint, coating, solvent storage workshop air, will continue to float in the low-flashpoint volatile vapors. These media are extremely sensitive, and the slightest electrical spark, or high temperature surface of equipment, can trigger a risk of combustion or explosion.
All lifting equipment into the operating area, need to have explosion-proof attributes, to eliminate the common electronic control, mechanical structure of the safety hazards.
Grain and oil, powder processing plant
Flour, feed, sugar, starch and other powder processing, will produce a large number of fine suspended dust. After the dust gathering reaches a certain concentration, a dust explosion environment will be formed, which is a typical solid high-risk explosion-proof scenario.
Raw material transfer, equipment maintenance, finished product lifting dust explosion-proof Crane, need to be targeted to do a good job of dust sealing, electrostatic discharge, temperature control protection, different from ordinary industrial lifting equipment.
Coal, carbon black powder plant
Coal processing, carbon black production, powder transfer stations, high dust concentration, accumulation speed, and high frequency of equipment operations, mechanical friction, electrostatic buildup of risk is prominent.
This kind of dust high-risk areas, must use explosion-proof cranes suitable for dust conditions, the open structure of the ordinary Crane is very easy to accumulate dust, sparks, can not meet the requirements of safe production.
Ordinary plants and conventional warehouses
Ordinary production workshops, finished product warehouses and logistics yards without flammable and explosive media and without the risk of dust accumulation belong to the conventional industrial environment. The operation process will not produce explosive atmosphere, no ignition source control just need.
This kind of scene does not need high-matching explosion-proof equipment, regular Overhead C ranes and Gantry Cranes can fully meet the lifting needs, more cost-effective, more convenient operation and maintenance.
Core operational requirements of hazardous area projects
The core of lifting operations in high-risk scenarios is not to improve lifting efficiency, but to avoid the risk of explosion in all aspects. All the equipment selection, operation specification, operation and maintenance standards, are centered on the control of hazardous sources.
All-round control of ignition sources
The core cause of industrial explosion is all kinds of controllable ignition sources, including electrical sparks generated by the start and stop of electrical fittings, mechanical sparks generated by the friction and collision of equipment, high temperature surfaces formed by long-term operation, and accumulation of static electricity.
All the design optimization of Ex cranes used in hazardous areas revolves around the elimination of ignition sources, eliminating potential safety hazards from the structural and accessory levels.
Equipment adapted to the risk of real working conditions
You can't define the type of equipment based on the industry of the plant alone, and the same plant will be divided into hazardous and safety zones. Part of the chemical plant office, warehousing area without high-risk media, no explosion-proof equipment; while the production process area must be strictly adapted to explosion-proof models.
The core of the selection is the real environment of the equipment operating point, rather than the overall industry attributes of the plant.
Distinguish between gas risk and dust risk scenarios
Gas explosion-proof and dust explosion-proof are two completely independent systems, protection structure, certification standards, design logic are different. Gas scenarios focus on electrical sealing, spark prevention and control, dust scenarios focus on dust, temperature control, static electricity export.
Mixed use of equipment can lead to protection failures, which is the main reason why many projects fail acceptance and leave hidden safety hazards.
Take into account the practicality of equipment operation and maintenance
Explosion-proof equipment can not only pursue the level of protection, excessive closure, structural complexity of the protection design, will significantly increase the difficulty of daily maintenance, parts replacement.
Qualified hazardous area Crane, will be under the premise of safeguarding explosion-proof safety, set aside a reasonable space for operation and maintenance, suitable for long-term normalized operation and maintenance needs.
Complete compliance qualifications and technical documents
Global high-risk industrial projects, explosion-proof equipment is extremely strict compliance audit. Equipment must have the corresponding level of explosion-proof certification, exclusive marking, a full set of technical drawings and accessories compliance documents.
These materials are the core basis for project acceptance, compliance filing, overseas customs clearance, ordinary Cranes do not have such qualification documents.
Long-lasting spare parts and exclusive after-sales protection
The spare parts of explosion-proof equipment are exclusive customized models, which can not be common with ordinary Crane spare parts. The risk of equipment downtime in high-risk scenarios is extremely high, requiring manufacturers to provide a long-term stable supply of spare parts and professional after-sales guidance.
The basic definition of the two types of Crane and the applicable scenarios
Many purchasers can not accurately distinguish between the core positioning of the two types of equipment, in short, ordinary cranes serve regular industrial scenes, explosion-proof cranes exclusive of various types of high-risk hazardous areas.
What is explosion-proof Crane?
Explosion-proof Crane is a special lifting equipment specially designed for explosive hazardous environments, the entire machine from the motor, electronic control, cable, braking system to the mechanical friction structure, all using explosion-proof exclusive configuration.
The equipment can effectively inhibit electrical sparks, mechanical sparks, high temperature surfaces, static buildup and other ignition sources, suitable for gas, steam, dust and other types of high-risk explosive environments, fully meet the ATEX, IECEx and other global explosion-proof compliance standards.
What is an ordinary Crane?
Ordinary industrial cranes are conventional general-purpose lifting equipment, only to meet the basic lifting, transfer, overhaul functions. Equipment accessories, electronic control system, mechanical structure are general industrial configuration, without any explosion-proof protection design.
This type of equipment is only suitable for ordinary workshops and storage scenes without flammable and explosive media, no risk of explosion, simple structure, low cost, convenient operation and maintenance.
Prioritize the use of explosion-proof Crane scenes
Work area perennial or intermittent combustible gases, volatile vapors, suspended combustible dust, the formation of explosive atmosphere conditions. Equipment running track, operating range covering the calibrated hazardous area, need to enter the high-risk areas throughout the operation.
The local supervision of the project requires the equipment to have Ex explosion-proof certification, hazardous area compliance qualification, such scenes must be a full set of explosion-proof lifting equipment.
Ordinary Crane is fully adequate for the scene
The factory area has been professionally surveyed, is a non-hazardous ordinary area, normal production operations will not produce any explosive gas or dust atmosphere. Equipment throughout the safe area operation, will not enter any calibration of high-risk areas.
Conventional warehousing, machining, assembly workshop and other non-explosion-proof requirements of the working conditions, the choice of ordinary Crane more cost-effective, fully meet the production requirements.
Adaptation program for mixed working conditions
Many large factories exist in the working conditions of the partition, the safety of the region using ordinary cranes to complete routine operations, only high-risk process areas, maintenance points configured with explosion-proof lifting equipment, partition adaptation, according to the need for selection, balancing safety and cost.
Part of the project does not require the entire machine explosion-proof, only the electronic control, motor and other core spark-prone components need explosion-proof configuration, can be used with ordinary Crane local explosion-proof accessories customized solutions.
Core differences between explosion-proof cranes and ordinary cranes
The appearance of the two types of equipment, lifting function similarity is very high, but the core design, safety standards, adaptable working conditions have essential differences, but also procurement selection must focus on checking the content.
Applicable working conditions are different
Explosion-proof Crane is designed for various types of hazardous areas, can be adapted to oil and gas, chemical industry, painting, powder and other flammable and explosive high-risk scenarios, can be in the high temperature, dust, corrosive, explosive and stable operation of complex environments.
Ordinary Cranes are only adapted to regular room temperature, no flammable and explosive media, no high-strength dust in ordinary industrial environments, can not withstand the safety risks of high-risk working conditions.
Different configurations of core parts
All core accessories of explosion-proof Cranes are exclusive explosion-proof models, including explosion-proof motors, explosion-proof brakes, explosion-proof limit switches, sealed electronic control boxes, flame retardant explosion-proof cables, explosion-proof operating handles and remote control systems.
All electrical and mechanical components that are prone to sparks and high temperatures are designed with explosion-proof modifications. Ordinary Cranes use common industrial parts without any sealing, flame retardant, explosion-proof optimization treatment.
Ignition source control capability is different
The core of explosion-proof Crane design is to eliminate all potential ignition sources, through the sealing of explosion-proof, safety protection, intrinsic safety design, electrostatic discharge, material optimization and other ways to eliminate sparks and high temperature generation.
Ordinary Crane has no ignition source control design, equipment start and stop, friction, electrical failure process, it is very easy to produce electrical sparks and mechanical sparks, in high-risk environments will directly lead to safety accidents.
Compliance certification requirements are different
Explosion-proof Crane is a special compliance equipment, must pass the professional explosion-proof testing, hold the corresponding regional explosion-proof certification, working condition suitability certificate, equipment level marking, supporting complete technical documents, to meet the acceptance criteria for all types of high-risk projects around the world.
Ordinary Cranes only need to meet the basic industrial lifting equipment standards, without explosion-proof certification and compliance information, the entry threshold is lower.
Different equipment cost
Explosion-proof Crane's customized accessories, explosion-proof structural design, compliance testing process, exclusive process standards, will increase production costs, the overall offer is much higher than the same tonnage, the same span of ordinary Crane.
Ordinary Crane mass production of high degree, common accessories, simple process, procurement costs and lower landed costs, suitable for regular working conditions batch selection.
Different maintenance standards and difficulties
Explosion-proof Crane maintenance requirements are more stringent, you must use the original explosion-proof special parts, overhaul process, replacement cycle, operating norms have clear standards, improper maintenance will directly damage the explosion-proof performance of the equipment.
Ordinary Crane maintenance process is simple, strong generality of accessories, conventional factory operation and maintenance personnel can complete the daily maintenance and replacement of accessories.
Selection decision logic is different
Professional selection will not be based on experience or subjective preference for equipment, but the site hazardous area survey report, the type of hazardous sources, the scope of operation as the core basis. Eliminate the risk of under-matching and avoid the cost waste caused by blindly over-matching.
Core technical parameters that must be verified for procurement
No matter which model you choose, you need to check the core parameters with the project conditions to ensure that the equipment is suitable for the production needs and meets the compliance standards at the same time.
Hazardous source type
Make it clear whether the site is a single source of gas, vapor, mist, dust, or a mixed source of gas and powder. Different hazardous sources correspond to different explosion-proof standards, which directly determines the direction of equipment selection.
Hazardous area level
Check the project survey labeled area properties, distinguish ordinary non-hazardous areas, gas 0/1/2 area, dust 20/21/22 area, the equipment protection level must accurately match the area level.
Rated lifting tonnage
Calculate the tonnage according to the self-weight of the lifted goods, the weight of the spreader, the maximum operating load, and reserve a reasonable load margin to avoid long-term full-load operation affecting the stability of the equipment.
Equipment span
Strictly match the center distance of the workshop track, plant layout and operation coverage to ensure the smooth operation of the equipment, no blind zone, and adapt to the site civil construction conditions.
Effective lifting height
Combined with the equipment lifting path, cargo stacking height, plant floor height, and safety spacing to determine, to meet the height requirements of daily production lifting and equipment maintenance.
Working level
Differentiate the use of equipment, whether it is low-frequency equipment maintenance lifting or high-frequency normalized production lifting, different operation frequency corresponds to different equipment working level, to ensure the durability of equipment.
Environmental conditions
Comprehensively consider the site environment temperature, equipment surface temperature control needs, humidity, dust accumulation, corrosive media and other factors, targeted optimization of equipment protection configuration.
Equipment control mode
High-risk hazardous areas are prioritized to use wireless remote control to reduce the risk of personnel working in close proximity; common areas can choose handle control, cab control and other conventional modes.
Mechanical risk point protection
Focus on verifying the protection design of brakes, traveling wheels, transmission friction points and metal contact parts to avoid mechanical friction sparks and high temperature risks.
Electrical protection principle
Clarify the electrical protection mode of the equipment, confirm that the protection design is suitable for the hazardous working conditions at the site, meet the local explosion-proof compliance requirements, and ensure long-term stable operation.
Reliable Crane Supplier Screening Criteria
Ordinary Crane manufacturers can not land the customization and production of explosion-proof equipment, high-risk project selection of suppliers, focusing on verification of industry-specific experience and landing capacity.
Verification of hands-on experience in hazardous area projects
Priority is given to manufacturers with a large number of explosion-proof project landing experience, as distinguished from manufacturers who only produce ordinary Cranes. Manufacturers must be familiar with the design standards and compliance requirements for all types of gas and dust high-risk conditions.
Verification of similar industry landing cases
Focus on checking the manufacturers in the oil and gas, chemical, coating, grain and oil powder, new energy and other high-risk industries, real project cases, to verify the suitability of equipment conditions and project landing capacity.
Evaluation of professional engineering adaptability
High-quality manufacturers will take the initiative to determine whether the project needs explosion-proof equipment according to the customer site conditions, distinguish between explosion-proof and local explosion-proof, to give a cost-effective cost-effective selection of the project, rather than simply promote the high allocation of equipment.
Verification of a full set of professional and technical information
Regular manufacturers can provide a full set of equipment assembly drawings, electrical schematics, explosion-proof marking instructions, compliance certificates, core accessories parameters, operating manuals and other information to meet the global project acceptance requirements.
Confirmation of core component brands and compliance
Verify the brands and explosion-proof qualifications of explosion-proof motors, brakes, limit switches, electronic control systems, cables, operating accessories, and all core accessories must be compliant with the standards, and eliminate low-match replacement.
Clarify the scope of testing and commissioning services
Confirm the manufacturer's factory testing, performance testing, on-site installation guidance, machine commissioning, personnel training and other services, to ensure that the equipment can be put into production in a compliant manner after entering the field.
Verify compliance coverage
Confirm in advance whether the equipment is the whole machine explosion-proof compliance, or local accessories explosion-proof adaptive, matching the project regulatory requirements, to avoid non-compliance with the scope of compliance leading to acceptance failure.
Verification of after-sales and spare parts protection
Exclusive accessories for explosion-proof equipment with poor generality, manufacturers need to have long-term spare parts inventory, fast after-sales response, remote operation and maintenance guidance capabilities to reduce equipment downtime losses.
Procurement selection of common misconceptions
Many of the project's safety hazards and cost waste, are derived from the cognitive bias in the procurement stage, these high-frequency misunderstandings can be effectively avoided.
Mistakenly believe that all industrial plants need explosion-proof Crane, blindly high allocation of equipment, significantly increasing the project procurement costs.
Luck, in the calibration of the dangerous area using ordinary Crane, direct contact with the red line of production safety, buried a major explosion hidden danger.
Confuse gas explosion-proof and dust explosion-proof conditions, misallocation of equipment types, resulting in equipment protection failure.
Simply select the type at a low price, ignoring the qualification of equipment compliance and quality of accessories, the equipment can not pass the project acceptance.
Blindly over-selecting equipment without verifying the real source of hazards on site, resulting in redundant equipment performance and wasted budget.
Unable to accurately determine the operating range of the equipment, mistakenly classified ordinary equipment into the hazardous area operation.
Only verify the explosion-proof qualification of the whole machine, ignoring the compliance of the core parts, and there are protection loopholes.
Failure to plan in advance for long-term maintenance and spare parts replacement program, equipment later explosion-proof performance gradually failed.
Frequently Asked Questions
What is the core difference between explosion-proof cranes and ordinary cranes?
The core differences between the two focus on design logic, parts configuration, safety protection and applicable working conditions. Ordinary cranes only meet the basic lifting function, no explosion-proof design; explosion-proof cranes from the machine structure, electrical systems, mechanical components, all-round avoidance of ignition sources, exclusively adapted to the flammable and explosive hazardous areas, and have formal explosion-proof compliance qualifications.
All high-risk areas must use explosion-proof Crane?
No. Only the labeled hazardous areas need to use explosion-proof cranes. Only standardized hazardous areas require explosion-proof equipment, ordinary storage, office, non-process areas in the plant, no explosive media and atmosphere, the use of ordinary cranes can be, without the need for mandatory high matching.
Can ordinary Crane be used around the hazardous area?
If the equipment is running in the safe area throughout the whole process, the operation range and operation track will not enter the hazardous area, and will not contact with high-risk media, ordinary Cranes can be used normally. Once the operation track covers the hazardous area, the explosion-proof equipment must be replaced.
Explosion-proof Crane purchase price must be higher?
With the same tonnage and the same span, the cost of explosion-proof Crane is generally higher than that of ordinary Crane. Exclusive explosion-proof accessories, modified design, compliance testing, and customized processes all add to the production cost, but the safety value and compliance they bring cannot be replaced by ordinary equipment.
What project information needs to be provided to the manufacturer before requesting a quotation?
You need to provide the industry you belong to, the type of hazardous source on site, the grade of hazardous area, the required tonnage of the equipment, span, lifting height, operating conditions, the location of the project and the drawing of the plant, so as to facilitate the manufacturers to accurately judge the model and match the compliance program.
How to determine whether the operation area is a hazardous area?
It can be determined based on the project's professional safety survey report, plant area demarcation markings, and the properties of the production medium. Areas where there are combustible gases, volatile vapors, combustible dusts and explosive atmospheres may be formed are high risk hazardous areas.
Can the same manufacturer provide both ordinary cranes and explosion-proof Cranes?
Professional lifting equipment manufacturers can provide one-stop general industrial cranes and a full range of explosion-proof cranes to meet the operational needs of the plant zoning, unified equipment standards and after-sales system to reduce the cost of operation and maintenance of the project.
Summarize
Explosion-proof cranes and ordinary cranes selection, the core basis is always the site of the real working conditions, rather than purchasing habits, project name or subjective perception. There is no absolutely better equipment, only more suitable for the project model.
Purchasers need to accurately distinguish between ordinary work areas and high-risk hazardous areas, identify the type of gas and dust hazards, and then match the corresponding Crane models, technical parameters and compliance standards, neither risky low matching, nor blindly high matching.
Reliable equipment suppliers can not only provide compliant lifting equipment, but also with rich global project experience, to provide customers with working conditions assessment, selection guidance, compliance docking, installation and commissioning, long-term operation and maintenance of the whole process of services, to ensure that the project is safe to land, long-term stable operation.
Henan Mine Crane manufactured industrial lifting equipment for many years, can provide one-stop general industrial cranes, a full range of explosion-proof cranes, suitable for oil and gas, chemical, powder, grain and oil, new energy and other types of domestic and international projects conditions, to meet the ATEX, IECEx and other global compliance standards.
Not sure whether to choose explosion-proof cranes or ordinary cranes for your project? Provide your industry conditions, hazardous area information, equipment parameters and project drawings, our professional engineering team will customize an accurate and suitable selection plan for you.
