Control Room Containers for Potentially Explosive Areas

Challenge
Safe automation solutions for use in EX Zone 22.

For a power plant in the Philippines, gefeba was awarded the contract to supply all the electrical equipment for material handling for a total of eight machines. The systems operated entirely within EX Zone 22, which placed particularly high demands on safety, design, and certification. The control cabinets and operator panels were to be integrated directly into the machines via containers. To achieve this, safe areas had to be created within the control room containers where standard components for control, drive, and automation technology could be installed. At the same time, all systems had to meet the requirements of DIN EN IEC 60079 Part 13 as well as the applicable ATEX directives.

Solution
Pressure-sealed switchgear containers with comprehensive explosion protection.
gefeba developed and designed a total of eight switchhouse containers for use in potentially explosive atmospheres. The four 20-foot and four 10-foot containers were each designed as overpressure-encapsulated enclosures in accordance with DIN EN IEC 60079 Part 13. To ensure safe operation, the containers were equipped with airlocks and interlocked doors. An ATEX-certified overpressure system with special filter systems ensures at least five air changes per hour. Overpressure control is managed via variable-frequency drives. In addition, all cable entries were implemented in EX-rated versions. The air conditioning system and the installed, non-opening windows also meet the requirements of the ATEX directives and can withstand the required mechanical impact loads. In addition, gefeba integrated redundant Allen-Bradley L72 PLC controllers, operator consoles with Panel View, and comprehensive EX monitoring technology featuring pan-and-zoom EX cameras, network recorders, and video clients. Experts from DEKRA EXAM were involved as early as the design phase, ensuring that both certification and acceptance by the end customer could be secured following a successful FAT.
Result
Certified switchgear solutions for maximum safety

The specially developed control cabinet containers made it possible to create a safe area for modern control and automation technology within EX Zone 22. This solution enables the reliable use of standard components even under demanding explosive atmospheres. Thanks to its standards-compliant design, integrated overpressure technology, and comprehensive certification, a highly safe and maintenance-friendly solution for material handling in power plant operations has been created.

Project Type
Explosion-proof switchhouse containers for material handling
Services
Engineering, Control Panel Construction, Explosion Protection, Automation
Technologies
ATEX, Allen Bradley L72, Panel View, Overpressure Technology
Industry
Building Materials, Energy
Distinctive Feature
Pressure-sealed enclosures in accordance with DIN EN IEC 60079, Part 13
Operating Concept
Safe control room within EX Zone 22
Solutions
8 Switching Station Containers
Container Sizes
4 x 20-foot and 4 x 10-foot
Features
Double lock, air conditioning, explosion-proof monitoring technology
Feed-in
800 A, 460 V, 60 Hz
Certification
Germanischer Lloyd Type Certificate, DEKRA EXAM
Completion
2015

Why Customers
Choose to Work with Us

We develop customized solutions—from analysis through the engineering phase to commissioning and support. Our focus is on maximum functionality, on-time delivery, and durability.

Our project work is supported by collaborations with leading technology partners such as Siemens, Rittal, B&R, and Proxmox, which provide the technological foundation for our project results and help expand them.

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