Class 1 div 2 lighting in the power plant safety lighting applications

First, why must power plants use professional explosion-proof lights? –Rigid demand in high-risk environments

In this type of power plant involves high temperature and pressure, flammable and explosive substances in a special environment, Class 1 div 2 lighting are the core equipment to ensure safe production. According to the “Electric Power Safety Regulations” requirements, all explosive risk areas must be equipped with Ex d I Mb certified explosion-proof lighting equipment.

Coal power plant, for example, the fuel storage area methane concentration of about more than the lower explosive limit [LEL] 5%, while the traditional lamps produce 0.02 Joule electric spark can cause an explosion. Class 1 div 2 lighting approved triple protection mechanism to completely eliminate this hidden danger:

Explosion-proof shell: 8mm thick die-cast aluminum alloy, can withstand an explosion of 15MPa pressure shock

Intrinsically safe circuit: limit the circuit energy below 0.19mJ minimum ignition energy

Enhanced safety sealing: joint surface tolerance control within 0.05mm, protection level of IP66 or above

Actual cases show that a hydropower plant will replace the traditional sodium lamps for 200W LED Class 1 div 2 lighting, ground illumination increased by 30%, annual energy consumption decreased by 67%, maintenance costs reduced by 82%.

Second, explosion-proof lights in the power plant core application scenarios – the whole process of risk prevention and control

1 fuel and chemical processing areas

Coal silos, fuel tanks and other places to store a large number of combustible substances, Class 1 div 2 lighting need to have anti-static, corrosion-resistant properties. For example, BAD type Class 1 div 2 lighting adopts WF2 anti-corrosion coating, which can work stably for a long time in the environment of 95% humidity deoxidizer.

2. Power generation equipment-intensive areas

Boiler room, steam engine room and other high-temperature areas require lamps and lanterns with excellent heat dissipation performance. The latest design of Class 1 div 2 lighting approved aluminum substrate heat conduction + airflow heat sink dual technology, the operating temperature control in the range of -40 ℃ to +100 ℃, the light source life extended to 100,000 hours.

3. Emergency evacuation channel

Explosion-proof emergency lighting system needs to meet the 90-minute continuous power supply guidelines, illuminance is not less than 1lx. intelligent products can be linked to the fire alarm system, automatically switch the emergency mode and mark the escape path.

Third, the power plant explosion-proof light selection of the 5 Golden Guidelines

1. Certification compliance must be approved CNEX explosion-proof certification + coal safety mark [MA], give priority to IECEx/ATEX dual-certified products. 2.

2. Optical performance improvement advocating the selection of 120 ° wide-angle light distribution + Ra> 90 high color rendering index design, to facilitate equipment inspection. Let’s say a model explosion-proof lights approved nano-prismatic lens to implement uniformity of 0.7 or more.

• heat dissipation and protection design shell need to use high-pressure cast aluminum + sandblasting process, the heat dissipation area needs to reach the traditional lamps and lanterns more than 2 times, to ensure that the junction temperature ≤ 85 ℃.

4. intelligent control system with the help of DALI dimming protocol Class 1 div 2 lighting can save up to 40% of the energy consumption, integrated temperature and humidity sensors models more real-time monitoring of the environmental parameters.

5. full life cycle cost of 50W LED Class 1 div 2 lighting, for example, the total cost of 3 years than the traditional lamps and lanterns to reduce 57%, the payback period of only 11 months.

Fourth, technological innovation: from the cornerstone lighting to the hub of the smart power plant

1. Self-supply energy system breakthrough

2025 launched vibration power generation type explosion-proof lights, approved the collection of equipment vibration energy to implement off-grid power supply, has been implemented in a power plant coal conveyor trestle zero cable wiring.

2. Digital twin operation and maintenance

Unique ID chips are implanted in each luminaire, and the digital twin platform is approved to predict failures, shortening the maintenance response time from 48 hours to 2 hours.

3. Spectral Safety Monitoring

Adopting 430nm wavelength LED Class 1 div 2 lighting, it can detect methane concentration changeover in real time, with sensitivity up to 0.1%VOL, and warn the explosion risk 15 minutes in advance.

Fifth. Successful cases: a thermal power plant lighting retrofit benefit analysis

Shanxi, a 2 × 600MW unit power plant after the implementation of a comprehensive explosion-proof lighting upgrade:

Safety indicators: lighting-related accidents within three years to zero economic benefits: annual electricity savings of 4.28 million yuan, the equipment replacement cycle from 2 years to 8 years to extend the operation and maintenance effectiveness: intelligent management system to reduce the frequency of manual inspections by 70%!

Sixth, the future momentum: Class 1 div 2 lighting technology revolution in three directions

1. Material innovation: graphene heat dissipation module to reduce the weight of the lamps and lanterns by 40%, thermal conductivity efficiency by 300%.

2. Energy independence: photovoltaic – vibration composite energy supply system to implement 100% off-grid operation

3. AI Integration: Approved machine learning to improve lighting strategies and dynamically match equipment maintenance cycles.

Amasly Lighting, as a leading provider of explosion-proof lighting solutions, has provided customized services to power plants in many countries.

Our ExPro series products are approved for 97 extreme environment tests and equipped with an intelligent O&M platform, which can provide you with:

Free lighting diagnostic reports and full lifecycle cost simulation with 72 hour high speed response service.

Access to a customized lighting upgrade solution for your power plant

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