Innovative Ex ob Type Enclosure: Delivering a Custom IECEx-Certified Solution Under Tight Deadlines

JCE successfully manufactured and delivered a custom-built oil immersed resistor assembly, highlighting an exceptional blend of innovation, technical expertise, and the ability to meet stringent industry standards under tight deadlines. This project demonstrates JCE’s commitment to providing bespoke explosion-protected solutions tailored to customer needs.

A client in the oil and gas sector approached JCE with an urgent need. They required an IECEx-certified enclosure to house a high-power resistor used for starting a DC motor application in a Zone 1 hazardous area for a gas turbine generator’s emergency oil pump. Given the critical nature of the project, the team at JCE needed to ensure the system met all the necessary safety and operational standards.

The project was made even more challenging by its tight timeline, essential for preventing disruptions to critical gas and light condensate production operations. Drawing on over 15 years of expertise in bespoke hazardous area systems, including experience from the OFU1 project, JCE’s team successfully designed the product, managed its manufacture, and completed the IECEx certification process—meeting the client’s required timeframe.

• JCE’s ability to design this complex product from scratch to meet Zone 1 hazardous area requirements showcases not only technical proficiency but also agility in responding to urgent client needs.
• The oil-filled resistor enclosure system consists of multiple explosion-protected components, each selected and designed to ensure compliance with IEC standards.
• The assembly is specifically tailored for a DC motor application – a challenging environment requiring both robust construction and precise engineering.

Achieving IECEx certification on a short timeline is a significant accomplishment, considering the stringent testing, documentation, and compliance verification required.
The project involved close coordination with the certification body, efficient technical documentation preparation, and accelerated safety assessments to meet global standards.
JCE’s deep familiarity with regulatory requirements allowed for streamlined approvals, ensuring the client could deploy the solution without delays.

The success of this project is attributed to the strategic combination of explosion-protected (Ex) components, each designed for specific safety needs:

• Ex db Temperature Switch – flameproof protection, ensuring any potential ignition sources remain contained within the enclosure.
• Ex ob Resistor Enclosure – employs oil immersion, isolating potential sparks or hot surfaces from hazardous gases, providing a passive yet highly effective safety method.
• Ex eb Terminal Enclosure – increased safety by eliminating sparks, arcs and hot surfaces.

• Effective Heat Dissipation – the Ex ob resistor enclosure ensures the resistor operates safely by dissipating heat and preventing ignition risks.
• Reliable Explosion Prevention – by submerging electrical components in oil, this method creates a protective barrier against the surrounding explosive atmosphere.
• Proven Suitability for High-Power Applications – the Ex ob method is particularly beneficial for equipment where heat generation or sparks  are inherent, ensuring compliance with hazardous area safety standards.
• Alternative Safety Methods Considered – while Ex d (flameproof enclosures) and Ex p (pressurisation) were explored, Ex ob was selected for its efficiency, passive safety, and long-term reliability.

This project is a textbook example of integrating engineering innovation with rigorous compliance to create a safe, reliable, and efficient solution for hazardous environments. The successful outcome resulted in:

• On-time project delivery, preventing operational disruptions for the client.
• Full IECEx compliance, ensuring regulatory approval for safe deployment.
• Enhanced equipment reliability, reducing maintenance needs and operational risks.

The integration of explosion-protected components (Ex db, Ex ob, Ex eb) and oil immersion significantly enhanced safety by protecting potential ignition sources, and providing reliable explosion prevention. This system meets hazardous area safety standards, directly improving operational safety. Without the IECEx-certified solution, the client could have faced unsafe operations in a high-risk environment, leading to potential safety hazards and operational inefficiencies. While other safety methods like Ex d (flameproof enclosures) and Ex p (pressurisation) were considered, Ex ob was ultimately selected for its efficiency, passive safety, and long-term reliability, offering a more cost-effective and safer alternative.

A key takeaway from this project is the critical importance of flexibility and expertise in designing tailored solutions under tight deadlines. JCE’s ability to swiftly adapt and develop a complex system that meets rigorous industry standards—while ensuring compliance and safety—underscores the company’s strength in delivering bespoke solutions. Moreover, the thoughtful selection of the Ex ob method, balancing both safety and efficiency, highlights the value of strategic engineering in achieving optimal results for demanding applications

JCE’s expertise in explosion protection allows us to develop tailored Ex-certified solutions to meet the most demanding industry challenges. Whether you require custom enclosures, control systems, or hazardous area equipment, our team can deliver certified solutions that align with your needs and safety requirements.

Contact us today to discuss your hazardous area project and discover how JCE can provide a custom-engineered solution for your application.