LED Lighting for Oil and Gas Refineries
Refineries are dangerous environments. Safety is paramount. All too often we drive by a refinery at night and see the glow of high pressure sodium lighting. High Pressure Sodium is a light of low CRI and runs around 2700K. It is a terrible light source for an environment where safety is important. If there was ever an application for a better, safer light source, LED is the best option. Here's why...
1. Higher Quality of Light: LED lights are better sources of light for two reasons. First, the quality of light, measured as Color Rendering Index (CRI) is typically higher most if not all the times than the traditional light sources they replace. High Pressure Sodium's CRI is somewhere between 20-40. This is at the bottom end of the spectrum. LED starts at 70. A much better higher quality light. By having this higher quality, you produce a safer environment for your oil refinery.
2. LED Runs Cooler: Ever touch a fixture containing Metal Halide or High Pressure Sodium? We don't recommend it. These lights are better at producing heat than they are at producing light. That is why they are so inefficient. LED's run significantly cooler. The oil refining process is already hazordous as it is, thus you don't want to further worsen an already fragile environment. Therefore, they are less likely to be a safety concern because of high surface heat temperature and a great option to install in your refinery plant.
3. Save Energy - therefore - Save Money: A typical 400W Metal Halide or High Pressure Sodium fixture uses approximately 75% more energy than the LED product that would replace it. This is real dollars that you don't have to spend while maintain the same if not better light levels you currently have. The majority of our LED lights are rebate eligible, either registered under DesignLights Consortium (DLC) or Energy Star. All our lights are UL or ETL listed for safety. All our DLC lights come with either a 5 or 10 year warranty. Many utility companies offer rebates for DLC Qualified or Energy Star certified products, saving even more money. High use areas often see paybacks in less than a year. Contact us for a free quote and we can even do a customer payback analysis for you on your light fixtures.
Outdoor Refinery Lighting Systems
Outdoor Lighting systems in refineries typically consists of outdoor parking lots for employee parking and refinery lighting itself. The refinery usually contains flood lights, wall packs, jelly jars, vapor tight linear fixtures and explosion proof fixtures. Most tend to be HID light sources, such as Metal Halide and High Pressure Sodium. Most lights tend to be either 100W, 150W, 250W, 400W or 1000W.
There are 2 options when it comes to converting over to LED. You can retrofit your existing fixtures or you can replace your existing fixture. There are some basic questions you should ask yourself when trying to decide whether to replace or retrofit. Generally speaking, retrofitting is far more cost effective than replacing. Retrofitting allows you to re-use your investment in your existing fixtures. The retrofit kits themselves are ETL Listed and DLC Premium Qualified, They are safe and eligible for the highest rebates available from your utility company (rebates are supplied by your utility company. They are not always available, contact us and we can help you find all available rebates). However, you can not retrofit an existing explosion proof fixture. Some LED Vendors claim you can. And they are partially correct. You will have to send the retrofitted fixture into an accredited lab for retesting. Retrofit LED kits are certified for general purpose refinery lighting, but not for explosion proof fixtures. Call UL Labs or ETL Labs to confirm. Since safety is paramount, then don't retrofit those fixtures.
Our retrofit kits are built to last and are backed with a 10 year warranty. So in terms of reliability, there is no reason to choose a new fixture over a retrofit solution because your investment in either will not be shortened by shorter life cycle of the retrofit.
If your fixtures are old, failing or leaking water, then it does makes sense to replace your existing fixtures, Retrofit kits require a dry environment, installing them into a fixture that leaks or has yellowed lenses does not make sense.
Retrofit kits install in most (but not all) existing fixtures. There are always exceptions. Low pressure sodium fixtures can present a problem due to the nature and physical characteristics of those bulbs.
Lighting Products you find outdoors at a Refinery
Area Lights: These lighting products are also pole mounted, but the poles are typically shorter. You see this type of light in many parking lots. They can either be 400W or 1000W bulbs in each fixture, and are typically either metal halide or high pressure sodium. You can either replace the fixture with a brand new LED Area Lights or Commercial LED Flood Lights, or like the High Mast Light, you can retrofit the fixture with a LED Head and Driver.
Wall Packs: Mounted on the wall, wall packs also provide area lighting and location specific flood lighting. They tend to be smaller lights, typically no more than 400W and are either Metal Halide or High Pressure Sodium. Because of the UV light in these types of lights, the lenses tend to yellow, making them hard to retrofit. If you can, the retrofit kit solution is a good option. If the fixtures need to be replaced, you can choose a Wall Pack LED Fixture.
Street Light: Also called Cobra Heads, these fixtures are what you find on the streets of a residential neighborhood. They typically tend to be small wattage bulbs, under 400W. The most common of street lights are between 70W and 100W, and can be metal halide or high pressure sodium. With these lights, you can retrofit them with a LED Kit or replace then with a new LED Street Lighting Products.
Vapor Proof Linear Fixtures: These fixtures appear in hallways and stairwells, and are long linear fixtures typically contains fluorescent tubes. They are sometimes called vandal proof fixtures, because their lenses are somewhat indestructible. In the world of LED, there are similar type fixture, called Vapor Proof Technology, that allows for great general lighting and is also available with a vandal proof lens
Explosion Proof Fixtures: These fixtures are rated Class 1 Div 2 and are UL Listed. Their light engines are all LED, ensuring great visibility and safety. Perfect as either a high bay fixture or as a flood light, these Explosion Proof Lights will provide the safety and piece of mind you are looking for.