Date: April 3, 2024 9:25 am

Designing Control Panel Systems for Hazardous Areas

Designing Control Panel Systems for Hazardous Areas

Providing Safe Operations in Hazardous Environments

The continuous whirring of a manufacturing plant hums with productivity. But behind the scenes, a silent conductor that keeps the production lines running is the control panel.

For facilities operating in hazardous areas, these control panels become even more critical, ensuring safety and efficiency in environments where a spark could spell disaster.

Designing Control Panels for Hazardous Environments

That’s where Delta Rock come in. As qualified control panel designers, Delta have the knowledge and expertise to specify components that will meet the stringent requirements of hazardous environments.

Our CompEx qualified team have the expertise and experience to design and install electrical systems in hazardous locations. We provide peace of mind. We navigate a world of regulations and cutting-edge technology, with a constant focus on safety. Our focus is the safe operations for your workforce and business.

Designing systems for hazardous environments is challenging. It is crucial that the design, manufacture and the subsequent installation is undertaken with the upmost attention to detail and adheres to current regulations.

Safety First: A Higher Standard

Not all control panels are created equal. In hazardous areas; classified by the presence of flammable gases, dusts, or vapours, even a minor electrical issue can have catastrophic consequence.

Our job is to design panels that meet stringent safety standards, ensuring they can withstand the unique challenges of the various zoned hazardous environments.

This involves selecting explosion-proof enclosures, intrinsically safe components, and meticulous wiring practices.

Hazardous Zone Areas

Hazardous Zone Areas
Zone Type of hazardous material Frequency and duration of presences
0 Flammable gases, vapours, and mists Continuously or for long periods of time
1 Flammable gases, vapours, and mists Likely to occur in normal operation
2 Flammable gases, vapours, and mists Unlikely to occur in normal operation, but still sufficiently likely as to require controls over ignition sources
20 Combustible dusts Continuously or for an extended period of time or frequently
21 Combustible dusts Frequently during normal working operations
22 Combustible dusts Unlikely to occur and if it does it would not be for a long period of time


Beyond the Basics: Automation Expertise

Modern control panels are far more than just a jumble of buttons and lights. They’re the brains of the operating systems, housing Programmable Logic Controllers (PLCs) and Human-Machine Interfaces (HMIs), as well as various other forms of electrical hardware.

At Delta Rock we have the expertise that understand the intricacies of electrical automation. We have the capabilities to design control panels that not only manage processes, but also provide clear data visualisation and operator interaction and control.

Irrespective of the environment, creating the correct control panel system will ensure the smooth operation of your production. The brains of the control panel will assist you in identifying potential issues before they snowball.

Keeping Up with the Cutting Edge

The field of industrial automation is constantly evolving, using new technologies like wireless communication and cloud-based monitoring. Our team remain up to date with these advancements, incorporating them into our designs as appropriate.

Using cutting edge technology will future proof the control panel system we create, allowing them to adapt to the ever-changing needs of the manufacturing landscape.

The Thrill of the Challenge

Every hazardous environment presents its own unique set of challenges.

From the explosive atmospheres of chemical plants to the combustible dust of grain factories, each will have their own unique complexity of requirements to challenge how the system can operate.

We are pleased that with the experience and technical expertise we hold at Delta Rock, we have the capabilities to identify issues and solve complex problems.

Working across a range of industries sectors we have seen numerous production complexities, which has grown our technical capabilities and understanding.

We can design and install systems that are fit for purpose, safe and efficient for hazardous manufacturing environments.

We will always work with our customer to understand the day-to-day operational needs and functions of the facility, to ensure the system will deliver the objectives set.

The Reward: Keeping People Safe and Your Business Efficient

Obviously when designing control panels and automation systems the core focus is levied on keeping people safe. We ensure the control panels we design function flawlessly and meet the required electrical and hazardous regulations.

The importance of reliable and safe control panels operating in a manufacturing hazardous area is critical. Our control panel design will ensure your plant continues to operate efficiently, safely, and productively.

Delta Rock: Have the Capabilities to work in Hazardous Areas

Delta Rock has the capability and appropriate qualified and accredited design engineers, and CompEx engineers to provide support in the design and installation of electrical systems for Hazardous Areas, (Zone 0, 1, 2, 20, 21 and 22), which will comply with all of the appropriate regulations.

We have designed and worked on a variety of projects that need to meet Hazardous Zone Area conditions, across a range of industry sectors, including: Food & Beverage, Petrochemical and Manufacturing.

Are Your Manufacturing Operations a Hazardous Environment?

If your need to develop or update your automation control panel systems or require a new bespoke system to improve efficiencies and safety, then Delta Rock can assist you from concept, to design to installation.

It is important to note that the classification of hazardous areas is a complex process and should only be carried out by a qualified professional.

Contact us today – send your enquiry

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