Interconnection
Wired for protection T
he offshore environment is, by nature, hostile. Electrical infrastructure exists alongside pressurised hydrocarbons and equipment must operate reliably in a setting defined by constant vibration, high humidity, salt-heavy air and severe pressure swings. These conditions accelerate degradation and introduce fault conditions that are rare onshore. Even minor intrusions, such as saltwater ingress or internal condensation can lower insulation resistance and increase the risk of arcing. More than just environmental exposure, the inherent layout of offshore platforms concentrates potential ignition sources within a confined area. Electrical connectors, in particular, are used in junction boxes, motor control systems, instrumentation panels and increasingly in subsea equipment, all points where energy and environment intersect. This makes them a natural candidate for risk mitigation through precision engineering.
Explosion-proof by design The defining feature of explosion-proof connectors lies not in their robustness, but in their engineered failure containment. Unlike standard connectors, explosion-proof models are built to ensure that if ignition occurs inside the housing, it remains contained. This is achieved through flameproof (Ex d) design principles, cast or machined housings with flame paths that cool and quench expanding gases before they exit the enclosure. Flame paths are calculated to account for pressure rise, flame temperature and gas composition, and require exceptional manufacturing precision.
Hermetic sealing adds another layer of protection. Whether through glass-to-metal seals or moulded epoxy compounds, the goal is to isolate electrical contacts from the environment entirely. These seals eliminate the possibility of flammable gases entering the connector body, while also withstanding pressure cycles and aggressive media over years of use.
www.cieonline.co.uk Protection strategies
Explosion-proof design is not one-size-fits- all, and offshore systems often demand a careful balance between different protection strategies. Intrinsically safe (Ex i) designs are widely used for low-voltage equipment such as sensor networks, instrumentation loops and data links, where circuits are engineered to operate with such low energy that even a fault cannot ignite a flammable atmosphere. In contrast, flameproof (Ex d) connectors are built to withstand and contain internal ignition, making them the preferred option for higher-power applications like motors, pumps, and lighting. The choice between these two approaches depends not only on safety considerations but also on system architecture, zone classification and energy distribution.
Supporting either approach requires materials that can endure the extreme demands of offshore environments. Marine- grade stainless steels like 316L offer long-term corrosion resistance, while nickel-plated brass provides a reliable balance of conductivity and chemical durability.
At the same time, connectors must resist galling and micro-cracking, especially under repeated use or vibration. To meet these demands, some advanced designs incorporate polymer sealing systems and high-performance ceramics that extend operational life, improve strength-to-weight ratios and enhance performance in subsea or deepwater applications.
The role of standards
No explosion-proof connector reaches the field without passing stringent certification protocols. ATEX and IECEx standards govern not just the connector’s function, but the entire manufacturing and quality assurance process. Connectors are tested for pressure resistance, flame containment, ingress protection (IP66 and higher), corrosion exposure (salt fog testing), thermal cycling and drop impact.
Crucially, traceability is built into the process. Manufacturers must document every stage of production, material sourcing and quality checks. This allows operators to verify compliance down to the individual part number, an essential feature for both maintenance planning and audit readiness. As offshore facilities become more connected and automated, connector technology is evolving. Manufacturers are now embedding diagnostics into explosion- proof housings, sensors that detect moisture ingress, thermal buildup, or contact degradation before failure occurs. Smart connectors are moving from concept to field use, adding real-time insight to components that were once passive.
The architecture is also becoming more modular. Hybrid connectors that carry both power and data in a single sealed unit reduce the number of connection points and simplify installation.
The Amphenol Star-Line EX series, distributed by PEI-Genesis, is one example
Offshore oil and gas platforms are among the most complex and hazardous industrial environments. Every aspect of their design, from structural engineering to electronic control, must account for the ever-present risk of explosion. Electrical infrastructure and particularly the connectors form a crucial barrier against ignition. These components are not only required to deliver uninterrupted power and data, but to do so without introducing a spark, even under failure conditions. Here, Isaac Noble, European product manager at connector specialist PEI-Genesis, explores the importance of explosion-proof connectors.
of how explosion-proof connectors are evolving. Engineered for use in ATEX and IECEx Zone 1-rated applications, this series combines high current capacity with a robust, flameproof shell and quick-disconnect coupling, enabling both safety and ease of maintenance in the field.
Complementing this, advanced cable glands, such as those developed by Amphenol Energy play a critical role in sealing cable entries against moisture and gas ingress. Designed for both armoured and unarmoured cables, these glands ensure the integrity of flameproof enclosures while accommodating a wide range of cable sizes and configurations. Together, these technologies reflect the growing emphasis on system-level safety, where every interface, from connector to enclosure, contributes to ignition prevention and long-term reliability offshore. In offshore oil and gas, where the risk of ignition is ever-present and the cost of failure is immense, explosion-proof connectors stand as engineered safety barriers. They are active components in a wider ecosystem of ignition prevention. From flameproof housings and intrinsic safety design to advanced materials and smart diagnostics, these connectors are continually evolving to meet the demands of more complex, automated and high- performance offshore operations. To find out more about the wide range of explosion-proof connectors offered by PEI-Genesis, visit:
www.peigenesis.com.
Components in Electronics October 2025 47
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