An Expert Q&A with CEO Neil Peterson: The Importance of Explosion Proof Lights In Industrial Facilities

In a recent interview, our Digital Marketing Manager sat with Neil Peterson, CEO of LED Lighting Supply to discuss common explosion proof lighting challenges faced by harsh location facilities and the critical role proper lighting solutions play to ensure safe working environments. Neil shares his insights on the specifics of hazardous location area requirements and qualification considerations.

What is Explosion Proof Lighting?

Explosion proof lights provide a safe lighting solution in harsh locations and hazardous areas, reducing the risk of worker injury. These rugged explosion proof lights are designed to contain hazardous contaminants such as flammable gas, dust, or vapor, preventing the presence of open flames, sparks, and ignition.

“Explosion proof lighting fixtures are engineered to avoid potential explosions and are commonly designed in round or linear fixtures as a ceiling-mounted high bay light”, Neil explained.

The fixtures are outlined based on various levels of classes and divisions: Explosion Proof Class i Division 1 (C1D1) or Class ii Division 2 (C1D2) LED fixtures

• Class i: Hazardous areas with the presence of explosive gas or liquids at all times (C1D1)
• Class ii: Areas that may contain combustible dusts, explosive gas, or liquids inflicted on accident (C1D2)
• Class iii: flammable gases are present

All of the explosion proof fixtures at LED Lighting Supply are designed with superior strength and meet stringent testing for hazardous location projects, including UL844 certifications, IK10 impact ratings, and IP66 waterproof certifications.

What Are High Temperature Light Fixtures?

High temperature LED lights are engineered to operate in extremely hot or cold environments without fail. These heat-resistant fixtures are constructed to provide high-quality light coverage and a long-lasting operating life.

Neil shares that high temperature light fixtures are an ideal alternative to standard LED lighting that cannot survive in high-heat environments.

“Our long-lasting UL-rated lighting options are capable of performing in extreme temperature areas and have a longer life expectancy than standard LED lighting.”

Hazardous areas in facilities typically require high temperature light fixtures or explosion proof LED lights. Neil explains that high temperatures above 50 Degrees C cause significant challenges in industrial facilities such as shortened life expectancy and failed operations

“Our High Temperature Lighting Fixtures support these environments and operate in extreme temperatures for long periods. Our high-temperature, corrosive-resistant lights are designed with quality materials to withstand corrosion and operate in higher temperatures up to 150 Degrees C to meet OSHA approval requirements.”

In many cases, these hazardous environments also require Explosion Proof Lighting due to the explosive nature of the chemicals.

What is Considered a Hazardous Environment and What Are the Different Types of Hazardous Conditions?

Neil shares that hazardous locations are industrial areas where potential dangers exist due to the presence of flammable gas, dust, or other combustible materials.

“Proper lighting solutions in these locations are critical for worker safety. Common explosion proof lighting projects include oil and gas refineries, chemical facilities, manufacturing areas, and other industrial settings.”

Neil explains that there are two types of hazardous conditions: normal conditions and abnormal conditions.

“Normal conditions are met when hazardous materials are typically present, and the risk of ignition is considered. Abnormal conditions are referred to when hazardous materials may be inflicted by accident, posing potential risks to workers and the environment.”

Are There Any Safety Considerations Relating to Explosion Proof Lighting?

“Our customers have told us that worker safety is the #1 goal in industrial facilities and the risk of getting it wrong can have dire implications. Therefore, a reliable lighting system is essential.”

Neil stated that facility owners prioritize reducing fixture outages to provide the necessary amount of light for a safe workspace and look for energy savings with LED lighting fixtures.

“Our lighting options reduce the time it takes to replace fixtures so facilities can maintain worker production safely and save anywhere from 50-70% of energy usage over traditional HID lighting.”

Additionally, supporting your light fixtures with a reliable explosion proof rated junction box is key for safeguarding conductors in hazardous location areas. Commonly used for rigid threaded conduit systems, explosion proof junction boxes contain sparks and flames, control damage that may pose significant safety hazards, and protect equipment for optimal safety.

How Do These Safety Considerations Impact Industrial Lighting Solutions?

Neil explains that selecting the proper fixture wattage and lumen output is also imperative to provide the safest lighting levels.

“Most explosion proof light fixtures we come across in existing facilities are 20+ years old and difficult to upgrade. From an upgrade standpoint, existing light levels are typically poor since facilities are designed with high ceilings without powerful enough lighting. Our free lighting plans provide a report that shows the correct amount of fixtures required to light facilities properly and the cover of light a hazardous location can expect. Our dedicated product specialists and lighting plan team engineer these plans after reviewing space requirements with the customer to ensure the lighting layout and number of fixtures align with their facility needs.”

Are Explosion Proof Lights a Necessity for Industrial Projects?

“It depends. It is important to ensure that you are working with a team that has a deep understanding of hazardous lighting requirements. This includes when it is needed and when it is overkill. The cost of light fixture installation could be less than half of what it would be with explosion-proof lighting if that lighting type is not a requirement for the space.”

“With 15+ years of lighting experience, LED Lighting Supply is a trusted partner for facilities, gas refineries, and other industrial projects. We work with our customers to ensure they select the perfect lighting solution for their hazardous location project with exceptional product support”, says Neil.

“One of our primary product lines includes high-quality industrial LED lighting that requires minimal maintenance, prioritizes worker safety, and provides ample lighting to reduce the risk of worker injury.

What Are the Important Considerations When Selecting Explosion Proof Lighting Fixtures?

“Explosion proof lighting fixture classifications for hazardous areas come into play to maintain a safe working environment in facilities,” explains Neil.

“There are areas where the flammable gases are present all or most of the time under normal operating conditions which require Class 1 Division 1 Fixtures. The second environment includes areas where ignitable gases or vapors are not present under normal operating conditions or areas next to Class I, Division 1 locations where barriers, walls, or doors do not exist. These areas require Class 1 Division 2 Fixtures.”

Neil shares the additional considerations during the qualification process; existing wattage, voltage input, how the existing fixtures are mounted, and mounting height to ensure ample lighting coverage while reducing the risk of worker injury, improving energy efficiency by 50-70%, and lowering maintenance costs.

Are There Any Recently Evolving Explosion Proof Lighting Trends?

“Yes, absolutely. Metal halide lights are going away, and continue to disappear from the market over the next few years as they are phased out. The real benefit for industrial facilities is the improved worker safety that LEDs provide due to better light coverage and longevity of the light.”
Most industrial environments and hazardous locations have existing lights. Neil explains that retrofitting existing fixtures can be costly and may have limitations on the amount of light a retrofit can produce. The original fixtures need to be tested after the retrofit to ensure they retain their explosion proof lighting properties.

“From a cost and safety perspective, facilities are much better off replacing existing fixtures with new energy-efficient LED fixtures. The majority of our industrial customers go with new fixtures due to the cost savings over the long run. Further, a new fixture will always have superior longevity than retrofitting due to technology and durability improvements over the past few years.”

What Other Types of Products are Considered to Help Industrial Facilities Overcome their Challenges and Meet Lighting Requirements?

• Industrial Grade High Bays: Industrial-grade high bays are best for non-explosive, high-temperature warehouses and workspaces that need rugged, high-output light fixtures.

• Outdoor Area Lighting: Outdoor light fixture solutions are best for reducing low light levels and shadows in parking lots, material staging areas, and double as security lighting.

In What Way Do These Lighting Solutions Differ from Traditional Hazardous Location Lighting Options?

Traditional lighting types such as HID and metal halide have far fewer life hours than the equivalent LEDs, which have 20,000 – 30,000 life hours.

“Many of our LED fixtures offer up to 150,000 life hours and improved CRI for clearer light. Both of these attributes equate to reducing maintenance, energy costs, and risk of worker injury.”

What Impact Does the Proper Lighting Solution Have on Helping Facility Managers Achieve Hygiene, Safety, and Efficiency Goals?

“All of our explosion proof LED lighting fixtures are IP66-rated and vapor-tight, meaning that they are waterproof and designed to reduce contaminates such as dust inside of the fixture. This decreases the amount of contamination in the facility, leading to a healthier workplace and ease of facility hygiene.”

Neil shares that hazardous area lighting provides 3 main benefits:

• Energy Savings: LED lights improve energy savings anywhere from 50-70% over traditional HID or metal halide lighting
• Reduced Maintenance Costs: With an explosion proof lighting solution, costs are still incurred but greatly reduced due to the longevity of the fixtures
• Worker Safety: LED explosion proof lights are a safe alternative to metal halide and keep areas well-lit for optimal visibility.

Light quality is greatly improved with explosion-proof lighting. In most cases, you achieve optimal light coverage for workers in facilities and enhance worker safety.