Explosion Hazards: Flammable gases (e.g., methane, ethylene) require ATEX/IECEx-certified components.
Chemical Corrosion: Exposure to acids, alkalis, solvents, and hydrocarbons.
Extreme Temperatures: High heat (exceeding 150°C near reactors) and subzero conditions (arctic or deep-sea applications).
Mechanical Stress: Vibration, impact, and repeated flexing (e.g., pump stations, compressor lines).
2. High-Reliability Cable Assembly Selection Guidelines
2.1 Explosion-Proof Design and Certification Compliance
Explosion Protection Types:
Flameproof (Ex d): Suitable for Zone 1/2 areas (e.g., storage tanks, reactor peripherals).
Intrinsic Safety (Ex i): For Zone 0 hazardous areas (e.g., gas leak-prone zones).
International Standards:
ATEX 2014/34/EU: EU explosion protection directive.
IEC 60079: Global explosion protection standards.
GB 3836: China’s national certification (NEPSI).
2.2 Corrosion-Resistant Materials and Structural Design
Jacket Materials:
Fluoropolymers (FEP/PFA): Resistant to strong acids, alkalis, and solvents (ideal for acid wash units).
Polyurethane (PUR): Oil-resistant and durable for pump/valve areas.
Shielding and Insulation:
Double Shielding (braided copper + aluminum foil): Mitigates EMI from VFDs and high-power motors.
Cross-Linked Polyethylene (XLPE) Insulation: High-temperature resistance and dielectric strength.
2.3 Mechanical and Environmental Durability
Flexibility Optimization:
High-Flex Conductors: Multi-stranded fine copper wires for 100,000+ bend cycles (e.g., robotic arms).
Kevlar Reinforcement: Enhances tensile strength for offshore platform installations.
Protection Ratings:
IP68/IP69K: Waterproof and dustproof for high-pressure washdowns.
UV-Resistant Jackets: For outdoor pipelines and exposed installations.
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