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In flammable and explosive environments, if you’re not using a digital explosion-proof pressure sensor, it’s dangerous!
In industries such as chemical processing, oil and gas, and metallurgy, production sites are often filled with flammable gases, vapors, or dust. Any spark, overheating, or equipment failure can lead to catastrophic consequences. Pressure, as a core parameter of the process, directly determines the intrinsic safety level of the system through the reliability of its monitoring equipment. Using traditional non-explosion-proof or ordinary pressure transmitters in these hazardous areas poses significant risks: the enclosure cannot contain internal explosion propagation, electrical sparks may escape, and seal failure can allow medium ingress.
The digital explosion-proof pressure transmitter is a professional solution specifically designed for such high-risk environments. It organically integrates high-precision measurement, intelligent display, on-site calibration, and strict explosion-proof construction, ensuring data accuracy while minimizing explosion risks. Nexisense’s digital explosion-proof series products have proven their reliability and practicality in numerous flammable and explosive locations. This article analyzes the explosion-proof principles, technical advantages, and real-world application scenarios to help practitioners understand why “ordinary” is no longer safe in hazardous areas.
Hazardous Areas’ Extreme Requirements for Pressure Monitoring
Hazardous areas are classified into Zones 0/1/2 (gas) and Zones 20/21/22 (dust) based on the frequency and duration of explosive gas/dust presence. Zone 1 (where explosive gas is likely to occur occasionally or frequently) is the most common industrial site type, such as refinery areas, natural gas gathering stations, and chemical reaction workshops.
In these areas, pressure transmitters must simultaneously meet the following requirements:
Prevent internal sparks/high temperatures from igniting external explosive mixtures
Enclosure withstands internal explosion without propagating flame
Surface temperature below ignition temperature (T-class)
Corrosion-resistant, moisture-resistant, dust-resistant, vibration-resistant
Support intuitive on-site reading and quick parameter adjustment
Traditional equipment often only provides basic protection and struggles to meet all these requirements. Once leakage or electrical failure occurs, the consequences can be disastrous. Industry accident statistics show that explosions triggered by instrument explosion-proof failure are not negligible. Therefore, selecting strictly certified explosion-proof pressure transmitters has become a mandatory safety requirement.
Ex db II C T6 Gb is a common explosion-proof marking, meaning: Flameproof enclosure (db), suitable for the most hazardous gas group IIC (hydrogen, acetylene, etc.), highest temperature class T6 (surface temperature ≤85°C), equipment protection level Gb (suitable for Zone 1). This ensures safe operation in the most demanding explosive gas environments.
Core Technology and Safety Design of Nexisense Digital Explosion-Proof Pressure Transmitter
The product uses an industrial-grade high-precision pressure sensing element, combined with digital wide-temperature compensation and nonlinearity correction algorithms, achieving stable output across a wide temperature range of -40°C to +60°C with minimal temperature drift. Standard output is 4–20mA current signal, with optional HART protocol for remote parameter configuration, diagnostics, and multi-device networking, perfectly suiting digital factory transformation needs.
The explosion-proof structure is the highlight: the entire unit uses an aluminum alloy flameproof enclosure, precision-machined and pressure-tested to withstand internal explosion pressure without deformation or rupture. The sealing design achieves IP67 rating, effectively blocking dust, moisture, and corrosive gas intrusion. Electrical parts employ isolation and energy-limiting technology to prevent spark leakage.
The most intuitive user experience comes from the LCD digital display: real-time display of current pressure value (supports switching between multiple engineering units), clearly readable even in dim light or from a distance. On-site three-key operation allows quick adjustment of zero point, span, damping time, and other parameters without additional tools or power interruption, greatly improving commissioning and maintenance efficiency.
In terms of reliability, the product offers 200% FS overload capacity and 300% FS burst pressure limit, maintaining integrity even under water hammer or transient high-pressure shocks. Two-wire connection is compatible with existing systems for easy direct replacement and upgrade.
These images clearly show the robust structure of the aluminum alloy explosion-proof enclosure, the field readability of the backlit LCD display, and the standard installation of the sensor on pipelines or vessels.
Application Advantages and Scenarios in Typical Hazardous Areas
| Application Area | Advantages & Features |
|---|---|
| Oil & Gas Gathering and Wellhead Monitoring | Natural gas pipelines and wellhead pressure monitoring face explosive gases and extreme weather. T6 temperature class and IIC gas group certification ensure safe operation in high-risk media such as hydrogen sulfide. On-site display allows inspectors to quickly check pressure status without additional instruments. |
| Chemical Reaction & Fine Chemical Plants | Reactors, distillation columns, and storage tank areas are filled with flammable solvents and gases. Explosion-proof enclosure + high-precision measurement enables precise reaction pressure control to prevent overpressure explosions. HART communication supports integration into SIS safety instrumented systems for interlocking protection. |
| Metallurgy & Air Compression Systems | Blast furnace gas, converter gas, and compressed air systems also pose explosion risks. Excellent vibration and corrosion resistance, plus 200% overload capacity, handle gas pulsation shocks. |
| Environmental & Wastewater Treatment Processes | Biogas collection and anaerobic fermentation produce combustible gases like methane. IP67 protection and on-site calibration adapt to humid, highly corrosive outdoor environments. |
Tangible Benefits from Actual Deployments
After multiple companies upgraded their hazardous area installations with this product, feedback includes:
Field inspection efficiency increased by over 50% (no need for extra instruments to take readings)
Significant reduction in unplanned downtime (near-zero damage rate from overload/impact)
Convenient system integration (direct replacement of existing transmitters without rewiring)
Higher safety audit pass rate (complete explosion-proof certification documentation)
These changes not only enhance intrinsic safety levels but also reduce long-term operation and maintenance costs.
Frequently Asked Questions (FAQ)
| Question | Answer |
|---|---|
| What does the Ex db II C T6 Gb explosion-proof rating mean? | Ex db indicates flameproof enclosure (can withstand internal explosion without propagating flame); II C is the highest gas group (suitable for hydrogen and other most explosive gases); T6 means surface temperature ≤85°C; Gb is suitable for Zone 1 hazardous areas. |
| How to quickly zero/span calibrate on-site? | Use the three buttons on the housing and follow the LCD guidance. No disassembly or special tools required; usually completed in a few minutes. |
| Does it support remote parameter configuration? | Optional HART protocol supports remote parameter reading/writing and device diagnostics via host computer or handheld communicator. |
| How to use it in highly corrosive environments? | The aluminum alloy housing already offers good corrosion resistance. For extremely corrosive media, optional special coatings or isolating diaphragm versions are available. |
Conclusion
In flammable and explosive environments, the safety of pressure monitoring equipment is not optional—it is a lifeline. With its strict Ex db II C T6 Gb explosion-proof certification, robust aluminum alloy enclosure, intelligent LCD display, convenient on-site calibration, and high reliability, the Nexisense digital explosion-proof pressure transmitter fully safeguards production safety in high-risk areas such as chemical, petroleum, and metallurgy. It is not just a measuring instrument, but a reliable guardian of intrinsic safety in hazardous areas.
When ordinary equipment can no longer meet safety thresholds, choosing an explosion-proof solution that can withstand explosion tests is the true responsibility toward production, personnel, and the environment. In today’s pursuit of higher safety standards and digital transformation, such products are becoming an essential upgrade direction for industrial sites.
