In the volatile industrial environments of Kuala Lumpur and Selangor, a flameproof motor (Ex d) is a precision safety device. Over time, bearings wear, insulation degrades, and critical flame paths can become corroded or obstructed. Unlike a standard motor service, a Flameproof Motor Overhaul is a regulated engineering process. If the internal tolerances are altered by even a fraction of a millimeter during repair, the motor’s ability to contain an internal explosion is compromised, turning a safety asset into a site hazard.
EKG M&E Sdn Bhd provides specialized overhaul and reclamation services in strict accordance with MS IEC 60079-19 (the Malaysian Standard for explosive atmosphere equipment repair).
As an HVAC and Clean Air Specialist, we treat the motor as a pressure-vessel. Our overhaul process focuses on the "integrity of containment":
The "Flame Path" is the precisely machined gap where the motor’s end shields meet the frame.
The Service: We use calibrated feeler gauges and micrometers to verify these gaps. If a flame path is pitted or scratched, we perform Reclamation via selective metal spraying or precision machining to restore the gap to its original certified tolerance.
If the motor has burnt out, we perform a "Copy Winding" to the manufacturer's original specifications.
The Service: We utilize Class H Insulation and high-grade resins. Crucially, we ensure the winding temperature remains within the motor's Temperature Class (T-Rating) to prevent the external casing from reaching the auto-ignition temperature of gases in your plant.
We restore worn bearing housings (end shields) and shaft journals.
The Service: Instead of discarding expensive Ex-rated castings, we use Laser Alignment and metal stitching or plating to bring mechanical parts back to "As-New" concentricity, preventing shaft runout that could damage flameproof seals.
Every overhauled flameproof motor must undergo rigorous "Ex" verification before being returned to service:
| Test / Inspection | Purpose | EKG M&E Implementation |
| Flame Path Audit | Confirm explosion containment. | Documented Gap vs. Certification Sheet. |
| Insulation Resistance | Verify winding integrity. | 5000V Megger Testing & Polarization Index. |
| Vibration Analysis | Prevent mechanical friction/sparks. | Full FFT Spectrum Analysis & Balancing. |
| Hydrostatic / Pressure | Ensure structural integrity. | Case overpressure testing (if required). |
If your flameproof motor is driven by a Variable Frequency Drive (VFD), the overhaul must account for harmonic stress:
dV/dt Protection: We ensure the new windings are "Inverter Rated" to withstand the voltage spikes common in VSD systems.
T-Class Verification: We verify the internal thermistors are calibrated. When a VSD slows a motor down, its internal fan loses cooling capacity; the thermistors ensure the motor trips before it exceeds its safe temperature limit.
In Malaysia, the Department of Occupational Safety and Health (DOSH/JKKP) requires that all repairs to hazardous area equipment be traceable.
The Service: We provide a comprehensive Overhaul Report detailing all measurements taken (Before/After), the materials used, and the final test results. This report is essential for your annual site safety audit and insurance compliance.
The "R" Mark: Repaired equipment is marked with the "R" symbol on a new repair nameplate, identifying the service facility and the year of repair as per IEC 60079-19.
Turnkey MEP Capability: We handle the entire lifecycle—from onsite removal and Laser Alignment to the internal mechanical overhaul and final re-installation in your KL facility.
Certified Competency: Our technicians are trained in "Ex" repair methodologies, ensuring that your motor maintains its original certification (ATEX/IECEx/SIRIM).
Predictive Support: We don't just fix what's broken; we perform a Root Cause Analysis on bearing failures and winding burns to help you prevent future downtime.
Malaysia
