In flammable and explosive environments, the explosion-proof design of flange connectors must comprehensively consider factors such as structural strength, sealing performance, material selection, and installation processes to ensure reliable operation under extreme conditions and prevent explosions caused by leaks or electrical sparks. The explosion-proof design of flange connectors is based on the principle of flameproofing, using enhanced shell structural strength to withstand internal explosion pressures. The shell is typically made of high-strength alloy steel or stainless steel, and the wall thickness must be designed to withstand the explosion pressure generated when the internal explosive mixture is ignited without rupture. Simultaneously, the length, width, and height ratio of the shell must be reasonable to avoid localized stress concentration due to pressure overlap, which would reduce explosion-proof performance.
Sealing design is a critical aspect of flange connector explosion-proof design. In flammable and explosive environments, the flange mating surfaces must employ reliable sealing structures, such as metal gaskets, graphite gaskets, or specially designed sealing rings, to prevent the leakage of flammable gases or dust through the mating surfaces. The sealing materials must possess corrosion resistance, high-temperature resistance, and good elastic recovery properties to ensure that the sealing effect is maintained even after long-term use. Furthermore, the gap between the flange mating surfaces must be strictly controlled, typically within a specific range, to prevent the propagation of explosion flames to the external environment through the gap.
Material selection has a decisive impact on the explosion-proof performance of the flange connector. In flammable and explosive environments, flanges and connecting components must be made of materials that are corrosion-resistant, high-temperature resistant, and do not easily generate static electricity. For example, stainless steel, due to its excellent corrosion resistance and mechanical strength, is often used to manufacture flange housings; while copper alloys, due to their good electrical and thermal conductivity, are suitable for manufacturing conductive components to reduce the risk of electric sparks. In addition, the material surface must undergo special treatment, such as galvanizing or applying an anti-rust coating, to prevent a decrease in sealing performance due to corrosion.
The installation process is equally crucial to the explosion-proof effect of the flange connector. During installation, it must be ensured that the flange mating surfaces are clean and free of foreign objects, and that the bolt tightening torque is uniform and reaches the specified value to prevent excessive gaps or seal failure due to improper installation. Furthermore, for metal pipe flanges conveying flammable substances, proper cross-connection with conductive wires is required to ensure unobstructed electrical conductivity on both flanges, preventing accidents caused by static electricity accumulation. Meanwhile, cables used in explosion-hazardous locations must avoid intermediate joints. If unavoidable, intermediate joints must be placed in appropriately explosion-proof junction boxes for explosion protection.
The explosion-proof design of flange connectors must also consider environmental factors. Under high-temperature conditions, material sealing performance may decrease due to thermal expansion; therefore, materials with low coefficients of thermal expansion or compensating structures must be selected. In low-temperature environments, materials may become brittle; therefore, materials resistant to low-temperature brittleness or additional insulation measures must be used. Furthermore, for highly corrosive environments, corrosion-resistant materials or anti-corrosion coatings must be used to extend the connector's service life.
The explosion-proof design of flange connectors must also comply with relevant standards and specifications. During the design process, strict adherence to national and industry standards is required. For example, the explosion-proof marking for flameproof electrical equipment is "d," and its design must meet specific requirements. Simultaneously, certification and testing by authoritative institutions are necessary to ensure that the connector's explosion-proof performance meets the specified requirements.
The explosion-proof design of flange connectors in flammable and explosive environments is a systematic project that requires comprehensive consideration of various aspects, including structural strength, sealing performance, material selection, installation process, environmental adaptability, and standard compliance. Through scientific and reasonable design and rigorous manufacturing processes, the flange connector can be ensured to operate safely and reliably in flammable and explosive environments, providing strong protection for industrial production.
