When visiting an old customer last month, the workshop director of the other party pointed to the newly unpacked chemical fluid packaging machine and sighed: "The explosion-proof level of this equipment is written as high, but I always feel a smell when filling acetone." This is like a fish bone stuck in my throat - explosion-proof safety is not enough to just look at the parameter certificate. Today, I will talk to you from the bottom of my heart about our factory's eight years of experience in explosion-proof design of chemical fluid packaging machines.
The "iron triangle" rule of explosion-proof design
Everyone who has worked in the chemical industry knows that explosion-proof safety must be closely related to fluid characteristics. Last year, when we renovated the xylene filling line for a chemical company in Zhejiang, we found that the customer's original equipment only had explosion-proof treatment on the motor, and as a result, the volatile gas of the material leaked out along the screw gap. Now our chemical fluid packaging machine explosion-proof design pays attention to the "iron triangle":
1. Airtight battlefield: All material contact surfaces are secondary coated with fluororubber, and the screw propeller is transformed into a three-stage labyrinth seal. You may think that it is just a change of sealing ring? But we have measured that this structure can reduce the escape of volatile gases by 70%.
2. Static bandit suppression: Dual redundant static elimination modules are added to the filling head, and the conveyor belt is replaced with a conductive ceramic roller. Once when debugging for a pesticide factory, the worker Lao Zhao was still wondering: "My hair stood up when I poured the powder before, why is there no movement this time?"
3. Ventilation barrier: A micro positive pressure system is set up in the equipment cavity, just like wearing a gas mask for the dangerous area. Last month, when handling highly corrosive fluids, this system locked the acid mist with a pH value of 2.5 in the equipment.
Details that are easy to step on
The most feared thing about the explosion-proof design of chemical fluid packaging machines is "taking it for granted". Two years ago, a customer in Guangdong reported that the filling machine always reported gas concentration warnings. We sent people to the site to take a look - the equipment was well-made for explosion-proof, but the customer made three right-angle bends in the exhaust pipe for convenience. Later, we optimized the exhaust path to a 45-degree slope, and the number of warnings dropped immediately.
There was another more amazing incident: the non-explosion-proof socket of a paint factory was only three meters away from the filling port, and sparks came out when the workers charged their mobile phones. Now we have equipped the equipment with a five-meter explosion-proof radius logo as standard, and also posted cartoon warning stickers at key locations. The old masters all said: "This is worse than the red-headed documents in the safety manual!"
Is it more difficult to renovate than to build a new one? Try this trick
Many old factories are always worried when renovating chemical fluid packaging machines, and they think it is more cost-effective to buy new equipment. In fact, as long as we grasp the three key points:
·Breathing modification: retain the main frame of the equipment, and replace the plastic parts that are easy to accumulate static electricity with 316 stainless steel;
·Sectional isolation: use explosion-proof glass to divide the operation area and filling area into independent cabins;
·Smart sentinel: install a combustible gas monitor, and automatically cut off the power supply and start nitrogen flushing when the concentration exceeds the standard.
Last year, when we did ATEX compliance modification for a certain adhesive factory in Shandong, we relied on these three axes to modify the old equipment ten years ago to be safer than a new machine. When the customer's chief engineer took the gas detector to the workshop during the acceptance, he finally said: "You are wearing a bulletproof vest for the equipment!"
Explosion-proof safety is a "dynamic homework"
Don't think that you can rest assured after completing the explosion-proof design. We require customers to do a "health check" twice a month: touch the static discharge module to see if it is hot, smell the seal to see if it has a swelling smell, and listen to whether the exhaust system is breathing smoothly. A chlor-alkali plant insists on keeping equipment logs. In three years, it has prevented four potential leaks just from abnormal vibrations.
Recently, we are also developing an intelligent early warning system to install an "electronic nose" on the chemical fluid packaging machine. During the test last month, this thing smelled a butanone leak 20 minutes earlier than the manual inspection, which scared the on-site technicians and said, "Thanks to this ancestor's nose!"
Conclusion:
The explosion-proof design of chemical fluid packaging machines is like cooking Sichuan cuisine, which requires both fierce fire and slow cooking. From structural sealing to static electricity control, from hard-core transformation to daily maintenance, no link can be lost. The hard bones that our factory has gnawed over the years have been transformed into a set of practical solutions. If you are also worried about the packaging of hazardous fluids, welcome to the workshop for tea - let's talk about the doorway of explosion-proof safety slowly with the roar of the equipment!
