How Enercon Builds Panels That Survive Harsh Environments — A Behind-the-Scenes Look

Control panels that fail to protect internal components and maintain their rated functionality are simply not fit for purpose. In harsh environments, various external factors—such as extreme temperatures, humidity, dust, and corrosive substances—can dramatically affect the performance and lifespan of a control panel compared to one installed in an ideal setting with moderate temperatures, low humidity, and minimal environmental exposure.

At Enercon, we design and build control panels for clients around the world, including in some of the most challenging environments on the planet. These include:

• Offshore oil and gas: Constant moisture, sea spray, salt exposure, and vibrations from wave activity.

• Military deployments in desert locations: High heat, sand, and direct sun exposure. 

• Mining operations: Mud, high humidity, flooding, and fine dust.

• Industrial plants: Exposure to hazardous chemicals, combustible dust, and airborne debris.

When control panels aren’t built to endure the conditions they are placed in, the consequences can be severe—ranging from frequent shutdowns and costly maintenance to catastrophic equipment damage, fire, and risks to human health. These outcomes are not only dangerous but also expensive—and entirely preventable through thoughtful planning, smart design, and robust construction.

In this article, we’ll walk through Enercon’s approach to building control panels for harsh environments, including the materials we use, design strategies we follow, and critical components that ensure long-term performance.

Materials Matter: Building for Resistance

A reliable control panel begins with understanding the environmental hazards it must face—and selecting materials that can withstand them. Each harsh setting presents its own challenges, requiring specific material choices. Some examples include: 

• Marine and coastal environments: In this situation, corrosion, rust, and sea spray entering the control panel are major issues. To prevent corrosion from salt and sea spray, we use 316-grade stainless steel, which includes 2%–3% molybdenum for enhanced corrosion resistance.

• Chemical exposure (industrial, oil & gas): Protective coatings like galvanization, powder coating, or cathodic protection are essential. We may also use aluminum or fiberglass-reinforced polymer (FRP) for their high corrosion resistance.

• High-temperature settings: Panels in hot environments benefit from heat-reflective coatings, along with durable polyurethane gaskets and silicone that maintain structural integrity in extreme conditions.

Sealing: Keeping Hazards Out

To protect internal components and preserve functionality, control panels must be tightly sealed against external elements, including:

• Rain

• Snow and ice

• Sand and dust

• Mud and vapor

• Flyings and combustible dust 

Depending on the threat, we implement sealing solutions such as polyurethane or silicone foam gaskets, waterproofing seals, and cable glands. For larger intrusions—like textile flyings or small animals—grilles with various aperture sizes can be used. High ingress protection ratings (IP65 or IP66) help ensure that even fine dust and small particulates are kept at bay.

Meeting NEMA Standards

Enercon builds control panels to meet the rigorous standards set by the National Electrical Manufacturers Association (NEMA), which define the environmental resilience required for different use cases. We’ve discussed NEMA specifications in detail in previous articles [linked here and here.]

Some common examples:

• NEMA 4/4X: Ideal for outdoor use, with resistance to water, dust, and corrosion (Type 4X offers additional protection against corrosive agents). 

• NEMA 7–10: Designed for highly hazardous environments, including those requiring explosion protection or resistance to aggressive chemicals, solvents, and lubricants.

Enercon has extensive experience designing control panels to meet every relevant NEMA classification, ensuring compliance and performance.

Designing for Longevity

Proper design is just as important as material choice. Layout and internal configuration can significantly impact a panel’s ability to function in difficult environments. A well-designed control panel not only supports performance but also extends the overall system lifespan and reduces maintenance demands. Design flaws, on the other hand, can lead to hot spots, moisture accumulation, corrosion, and cross-contamination between circuits.

Some key considerations include:

• Temperature control: Thermostatically controlled heaters for cold climates, or heat exchangers, filtered fans, and AC units for hot areas help maintain safe operating temperatures and prevent overheating or freezing of components.

• Moisture and vapor management: Specialized vents reduce vapor ingress and moisture buildup while allowing for proper aeration. Drip shields and condensation drains may also be incorporated for additional protection in high-humidity or washdown environments.

• Sectional separation: Designing compartments for different voltage zones can contain damage or contamination to one area, preventing compromise of the entire panel. This isolation is especially crucial in mixed-use panels where hazardous and non-hazardous components coexist.

Rigorous Testing: No Compromises

At Enercon, our full-service design and testing facility puts every control panel through a rigorous testing protocol to ensure performance under stress and reliability in the field. These tests simulate real-world conditions that panels will face once deployed, identifying any potential points of failure before they reach the customer. Our testing procedures include:

• Insulation resistance: Ensuring electrical insulation can withstand voltage stresses.

• Environmental stress testing: Simulating harsh temperatures, humidity, and contaminants.

• Operational simulations: Verifying that all components and circuits operate as intended under load.

• Hi-pot (high potential) testing: Checking dielectric strength to prevent arc faults and short circuits.

We also perform visual inspections, continuity tests, and vibration assessments depending on the application. This comprehensive approach helps guarantee safety, longevity, and compliance with all applicable standards, including NEMA and UL where required.

While we take our testing very seriously, our team has also showcased the process in a more light-hearted way through a series of behind-the-scenes videos, offering a glimpse into the precision—and personality—that goes into every Enercon panel.

Conclusion

A control panel's ability to survive and function in harsh environments isn’t a matter of luck—it’s the result of expert engineering, careful material selection, and thorough testing. From choosing the right alloys and coatings to designing layouts that withstand temperature extremes and environmental contamination, every detail matters.

At Enercon, we’ve spent decades perfecting the art of building control panels that endure in the most extreme conditions. If you're planning a project in a challenging environment, we're ready to help—wherever in the world you need us. Get in touch with us today.