LED Explosion Proof Lighting - Hazardous Location Lighting Fixtures - C1D1 and C1D2 Lighting

Explosion Proof LED Fixtures: Their Applications and Benefits in Confined Spaces

Confined spaces have a complex and dangerous nature and usually present numerous risks for workers. These spaces can be very dangerous because they have inadequate ventilation that may promote the buildup of poisonous gases and vapors in the atmosphere. They are also unsafe because they make it difficult for people to escape during an emergency.

Back in 2015, The Occupational Safety and Health Administration (OSHA) put in place new safety standards for construction work carried out in confined spaces. Employers are now required to take extra caution to ensure the safety of their employees. The U.S. Department of Labor predicts that the new regulations will play an important role in protecting numerous construction workers every year.

Why Explosion Proof Lights?

Because of the hazardous nature of confined spaces, many businesses that operate in dangerous locations install explosion proof lights (EPLs) to prevent the combustion of flammable dust particles, vapors, and gases. The ever-advancing LED technology has widely contributed to the widespread adoption of explosion proof lights by making them more sturdy, reliable, and cost-effective.

At the moment, the worldwide adoption of explosion proof LED lights keeps increasing at an average yearly rate of 5.9%. According to research, by 2018, the adoption of explosion proof LED lighting will reach $206 million. Areas leading in the adoption of explosion proof LEDs are oil-related businesses in Europe, Africa, and the Middle East.

Explosion proof lighting plays a very important role in the industrial operations of hazardous locations. When used in confined spaces (locations with only a few entry and exit points), it greatly reduces the risks connected to explosive gases (such as methane, propane, and flammable dust particles) and helps to streamline the work carried out in these areas.

EPLs are usually found in different demanding locations such as oil and gas refineries and food processing facilities. Confined spaces are very complex in their nature because of their isolated and dark conditions. The presence of dangerous dust or gases further increases the risks of working in these environments.

The introduction of LED lighting in the hazardous location space has had a great impact on the performance of the industry's offerings and products. Thanks to LED technology, people who work in confined spaces are able to increase their dependence on the lights and carry out their day-to-day tasks with great efficiency.

One crucial thing you should be aware of when getting explosion proof lights is classification compliance. Companies must be aware of the fixtures’ approval ratings in connection with hazardous locations. According to OSHA, workplace accidents are normally caused by incorrect use of equipment and human error.

In order to prevent workplace accidents, the agency and other regulatory bodies (like the National Fire Prevention Association) have put in place specific guidelines that classify explosion proof lights into classes, divisions, and groups. The National Electric Code (which is also referred to as NFPA 70) specifies the installation components and the design of electrical systems but does not give guidelines on the performance of the work involved.

Explosion Proof Lights Have a Robust Design to Prevent Ignition

Explosion proof lights are specially designed to contain sparks in case of an explosion so as to prevent the explosion from escaping – hence the term “explosion proof.” During an explosion, the lights lower the risk of the explosive reaction from spreading or kindling volatile substances in the location. The fixtures typically feature thick casings that cover the luminaires. The thick casing can cover the entire panel or bulb. An explosion proof box can also be used to house the sensor and the switch.

Because of the way an explosion proof fixture is designed, it forces the gas to take a long, complicated route through different channels and pathways as it is cooled down to a safer temperature before being released. It is worth noting that explosion proof lights are not airtight and allow gases to enter their aluminum casings.

However, the main work of these lights is to stop an explosion from escaping, whenever one occurs. Explosions can easily cause grave harm to workers or kindle ignitable substances in a facility, leading to serious damage. Explosion proof lights are usually fitted with high quality rubber gaskets to prevent them from getting damaged.

Confined spaces provide a perfect environment for hazardous vapors and gases to accumulate. These areas are normally isolated, poorly ventilated, and quite difficult to service, compared to other sections of a facility.

Confined spaces are usually located away from the main operating area of the plant, which is why they are not easy to access. Because of their highly sensitive nature, explosion proof lighting must be utilized to get rid of (or significantly reduce) the probability of fire hazards.

Explosion proof lights are normally used in these areas:

• Chemical processing plants
• Food processing facilities
• Aircraft maintenance areas
• Enclosed fueling stations
• Paint spray booths
• Offshore oil and gas rigs
• Chemical storage units
• Ship tanks
• Grain silos

For a long time, hazardous locations used fluorescent, metal halide, and incandescent light fixtures. But these lights are not efficient and cannot meet the sensitive needs of hazardous working environments. They have short lifespans, get easily damaged when they operate under extreme temperatures, and lose their brightness very fast. They also require a lot of electricity to produce a lot of lumens. They must be handled very carefully as they can break easily because of the glass filaments and parts found inside them.

By comparison, LEDs are superior. Their average lifespan is 50,000 hours and they also have a high luminous efficacy (they only need a few watts to produce a lot of lumens). LEDs consume less electricity for every unit of light they generate and most produce more than 75 lumens per watt, which means you spend less on electricity and get more light. Compact fluorescents only produce 40-70 lumens per watt while metal halide lamps produce 75-100 lumens per watt.

Thanks to their robust and compact designs, LEDs can withstand rough treatment as well as vibrations. They do not use lead or mercury like some traditional lighting technologies so they don’t have a complicated disposal process.

Explosion Proof LED Lights Comply with the National Electrical Code

All explosion proof lights must be certified by the official regulatory institutions in order to be used in hazardous locations. In the U.S. and Canada, these institutions include Edison Testing Laboratories (ETL), Underwriters Laboratories (UL), and Canadian Standards Association (CSA).

Hazardous locations normally contain high amounts of combustible substances (such as fibers, dusts, vapors, or gases) in the atmosphere that may cause an explosion. Each type of explosion proof light is categorized according to class, division, group, and zone.

The National Electrical Code (NFPA 70) gives detailed information on each category of the approval rating for explosion proof lighting. The code specifies that lighting equipment must follow specific temperature requirements of an installation area. For instance, a light's operating temperature and that of its working elements must not be greater than the lowest threshold of the ignition temperature of the gases in the atmosphere of the facility.

Businesses that are interested in installing explosion proof lighting in their facilities must take time to understand the classification requirements of the lights. In the National Electrical Code, article 500 defines the class and division classifications while article 505 defines the classes and zones.

Class I division 1: Where flammable concentrations of combustible liquids, vapors, or gases are found in the atmosphere under normal working conditions.

Class I division 2: Where flammable concentrations of ignitable vapors, liquids, or gases are found in the atmosphere under abnormal working conditions

Class II division 1: Where combustible concentrations of flammable dusts are found in the atmosphere under normal working conditions

Class II division 2: Where flammable concentrations of ignitable dust are found in the atmosphere under abnormal working conditions

Class III division 1: Where easily flammable fibers or materials that produce ignitable particles are found in the atmosphere under normal working conditions

Class III division 2: Where easily combustible fibers or materials that produce flammable particles are found in the atmosphere under abnormal working conditions

When it comes to class and group ratings, these are the classifications:

Class I areas: These are categorized into group A (acetylene), group B (hydrogen), group C (ethylene and propane), and group D (propane, butane, methane, and benzene)

Class II areas: These are group E (metal dust), group F (charcoal and carbon), and group G (wood, plastic, starch, and flour)

Class III areas: These are not categorized into groups but comprise of sawdust and cotton

It is vital to use LED explosion proof fixtures that meet the needs of the specific hazardous location. Most of the time, the explosion proof fixtures that meet a higher classification usually surpass the requirements of a lower classification. For example, the lights that are ideal for a division 1 location can be used in a division 2 location for a similar class and group.

Benefits of Explosion Proof LED Lighting Over Traditional Metal Halide Explosion Proof Lights

A Long Lifespan, Which Results In Lower Maintenance Costs

LED EPLs have numerous benefits over conventional explosion proof lights. These fixtures have an average life expectancy of 50,000+ hours. Compact fluorescent lights have an average lifespan of 8,000 hours while metal halides have an average lifespan of 15,000 hours.

The high durability of LED explosion proof fixtures means they continue to give off their original lumens (or more than 70% of their initial lumens) for a minimum of 50,000 hours, and in some cases, 100,000 hours. Explosion proof LED lights are also more energy efficient than traditional explosion proof lights. A LED fixture for a hazardous location can use up to 90% less electricity than a conventional fixture. The long lifespan of LEDS and their sturdy design both contribute to lower operating and maintenance costs.

They Emit Less Heat and Lower the Risk of Accidents

LEDs are solid-state lighting devices and function reliably because of their heat-saving features. They only produce an average of 3.4 BTUs per hour and are not affected by low temperatures or humidity. Due to their ability to produce less heat, they reduce the likelihood of accidents in hazardous working environments. Fluorescent lamps typically release 30 BTUs per hour and their life expectancy is affected by very high or very low temperatures.

They Support Eco-Friendly Initiatives

Since LEDs are more energy-efficient than traditional lighting technologies, they reduce the demand on the power grid, and in the process lower greenhouse gas emissions. LEDs convert 95% of the energy they draw into light and only waste 5% as heat. Conventional lights, on the other hand, waste 95% of the energy they draw as heat and only convert 5% into light.

If your company is thinking of implementing eco-friendly initiatives, switching to LED technology is one of the best ways to go about it. LEDs do not contain dangerous substances and their disposal process isn't as costly as that of fluorescent lamps.

How to Pick the Right Explosion Proof Lights for Your Location

Manufacturers of LED EPLs offer a myriad of light fixtures to cater to different hazardous locations. Since these lights are built differently to follow different classifications of hazardous locations, businesses that use the wrong types of lights may increase the risk of accidents in their facilities. Flammable dust, gases, vapors, or fibers can be easily ignited and cause serious accidents.

LED manufacturers also make different explosion proof products to meet the standards and requirements of confined spaces. String lights are normally used for activities that require portable light options. To ensure total protection, these fixtures usually have long cords and plugs that are explosion proof. Hooks located at their tops allow people to latch them on scaffolds, bars, and other sturdy structures. The wattage for explosion proof string lights varies between 26-100 watts.

Explosion proof manhole lights are ideal for railcars, storage tanks, and other areas with limited entry points. These fixtures usually have a wide input voltage range: 100 to 277 volts. They feature a circular design which is supported by a large plate that is placed on the lip of the manhole opening. Explosion proof nozzle mount lights are mostly used in ship tanks and storage tanks where the man-way opening is no larger than 21 inches.

Explosion proof handheld flashlights are portable and wireless lighting fixtures that offer on-the-go lighting or can be used in confined spaces (with many obstructions) where standard explosion proof lights can’t be used. These light fixtures are normally powered by rechargeable batteries and have excellent features like non-slip grip and water resistance.

For large scale operations where permanent explosion proof lighting is needed, businesses can use explosion proof tank lights. These units typically use a cart, a tripod, or a tower for support. Workers use these lights during lengthy and meticulous inspections that require them to be on-site for long periods of time.

However, tower units are not as flexible as portable explosion proof lights and are not recommended for extremely confined spaces like small tanks. The good news is that the fixtures provide better light because they have bigger lamps. A single fixture can produce up to 20,000 lumens. Just like portable EPLs, explosion proof tower units come with explosion proof plugs and cords.

Use the Right Explosion Proof LED Lights In Your Hazardous Location

Some of the explosion proof lights we carry at MyLEDLightingGuide include:

• Explosion proof high bays
• Explosion proof floodlights
• Round explosion proof lights
• Explosion proof linear LED lights

Safety is paramount and using proper lighting in confined spaces keeps your workers safe and productive.