Hazardous Area Manufacturing
www.neci.com
New England Controls, a value added reseller for Emerson Automation Solutions, had a need for 19" Display HMIs at their chemical client site, Thermofisher. Due to the nature of the process both Class I, Div 1 and Class I, Div 2 rated equipment was needed for this green field start up.
Challenge
The project required close collaboration with architectural designers to determine optimal placement of each operator workstation. Modular developed custom enclosure designs to fit within tight spatial constraints while maintaining required area classifications. Equipment had to be delivered on a strict timeline, with coordination alongside sub-contractors to ensure smooth installation during deployment. The team also adapted to frequent and fast-moving design changes as the project evolved, all while managing and scheduling site certification through a UL-certified laboratory.
Result
Modular delivered multiple custom workstation solutions for classified areas, collaborating from design through installation to achieve Class I, Div 1 and Class I, Div 2 certifications while exceeding project timeline expectations.
Requirements
The project demanded tailored enclosure designs for both Class I, Div 1 and Class I, Div 2 zones, tight coordination with contractors and architects, and agile execution to meet evolving specs, strict timelines, and UL certification requirements. Every unit had to be chemically resistant, ergonomically sound in tight walkways, and field-certified by a UL-listed lab before commissioning.
Solutions Design
The solution included a range of NEMA 4X polished 304 stainless steel enclosures, offering strong chemical resistance and certification for use in Class I, Div 1 and Class I, Div 2 hazardous areas. Retractable keyboard valets were incorporated to maximize space in tight walkways, while customized mezzanine rail mounts ensured OSHA compliance on stairwells. Type X and Z purge systems featured ergonomically placed controls, and compression latches with gasket seals provided long-term pressure integrity. Modular keyboards allowed servicing or replacement without shutting down the system, and area-rated alarm sounders were included for operator notifications. Each installation received field certification to meet underwriting requirements.
Outcomes
Modular produced multiple customized classified area workstation solutions collaborating closely with multiple contractors from the plant design phase to final installation and site hazardous area certification. Class I, Div 1 and Class I, Div 2 certifications were met with multiple HMI and mounting designs while managing and exceeding project timeline expectations.
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