How to design explosion-proof workshops in chemical plants?

The design of explosion-proof workshops in chemical plants must strictly follow national and industry standards, with core elements including building layout, explosion control, structural protection, and systematic safety management, as follows:
🔥  1、 Design specification basis
National standards
Mandatory compliance with the "Code for Fire Protection Design of Buildings" (GB 50016), specifying the division of explosion hazardous areas and requirements for fire separation distance.
The dust environment shall comply with the "Dust Explosion Prevention Safety Regulations" (GB 15577), which stipulate the pressure relief area and equipment explosion-proof level.
Electrical equipment must comply with the General Requirements for Explosion proof Electrical Equipment (GB 3836) and match the characteristics of explosive media (such as IIB/IIC level, T1-T6 group).
🏗️  2、 Architectural layout and zoning
Hazard isolation
Explosion hazardous equipment is centrally arranged in independent areas and isolated from non explosion proof areas using blast resistant walls (≥ 200mm reinforced concrete).
The workshop site should be located away from densely populated areas (with a safety distance of ≥ 50 meters), and the direction of pressure relief should avoid traffic arteries and critical facilities.
Space optimization
Explosive hazardous processes are located on the top floor of a multi story factory building, and flammable equipment is placed against the exterior wall to facilitate explosion venting.
💥  3、 Explosion Relief and Anti explosion Design
Pressure relief facilities
The ratio of pressure relief area to plant volume is 0.05-0.10 m ²/m ³, and lightweight roofs (self weight ≤ 60kg/m ²) or explosion-proof exterior walls are preferred.
The pressure relief wall requires directional blasting (activated when overpressure is 0.02-0.05 MPa), with fragment size ≤ 5cm, to avoid secondary damage.
Explosion resistant structure
The load-bearing frame adopts reinforced concrete structure, and the walls are filled with lightweight fireproof materials (such as rock wool sandwich panels).
⚡  4、 Key system protection
Ignition source control
Electrical equipment is fully explosion-proof (Ex d Ⅱ B T4/Ex d Ⅱ C T6 grade), and cable conduit holes are sealed with explosion-proof gland heads.
The grounding resistance of the equipment is less than 4 Ω, the pipeline flange is cross connected to prevent static electricity, and the liquid flow rate is limited to prevent friction and electrification.
Ventilation and Monitoring
Install an explosion-proof positive pressure ventilation system to maintain a slight positive pressure inside the room and block the intrusion of flammable gases.
Install combustible gas detectors in explosive hazardous areas, and issue real-time alarms when the concentration exceeds the limit.
🛠️  5、 Operations and emergency measures
Equipment maintenance
Regularly inspect pressure vessels, safety valves, etc., and replace corroded pipelines in a timely manner.
Emergency design
Evacuation channels with a width of ≥ 1.4 meters, equipped with gas masks and explosion-proof emergency equipment.
Organize at least 8 hours of explosion-proof drills every year to enhance personnel's emergency response capabilities.
Core principle: Achieve intrinsic safety through a four layer defense system of "anti mixing (controlling the three elements of explosion) - source control (eliminating ignition sources) - pressure relief (directional release of energy) - anti explosion (structural protection)". The design needs to be dynamically adjusted based on the process risk level and regularly verified for compliance.