Explosion proof led lights in the boiler room lighting applications

1. Boiler room lighting special challenges and explosion proof led lightscore value

Boiler room as a power plant, chemical plants and other industrial facilities in the core area, there are gas leakage [such as natural gas], high-temperature steam [up to 500 ℃] and dust accumulation and other multiple risks.

According to GB50058-2014 “Design Code for Electrical Installations in Explosive Hazardous Environments”, the gas boiler area is defined as an IIA/IIB explosive gas environment Zone 1, which must use Ex d IIB T4 and above explosion-proof lighting equipment.

Traditional lighting fixtures in such environments are prone to explosions caused by electric sparks, while the professional design of explosion proof led lightsapproved by the multi-protection structure, the surface temperature can be controlled in the T6 group [≤ 80 ° C] within the safety range, into the boiler room safe operation of the necessary equipment.

Boiler room lighting three core requirements

Intrinsic explosion-proof performance: need to block the lamps and lanterns internal circuit sparks and external combustible gases [such as methane, hydrogen] contact

High-temperature resistance: the lamps need to work in a stable ambient temperature of 50-150 ℃, the heat dissipation structure needs to meet the requirements of the LED chip temperature rise control.

Chemical corrosion protection: to deal with steam condensate, hydrogen sulfide and other corrosive media, the shell needs to be die-cast aluminum + nano-spray process, anti-corrosion grade of WF2

2 explosion proof led lights technical characteristics and boiler room scenarios adaptable program

2.1 Explosion-proof structure innovation design

For the boiler room environment, explosion proof led lightsusing explosion-proof [Ex d] and increased safety [Ex e] composite protection:

Multiple explosion-proof barriers: die-casting aluminum shell thickness ≥ 5mm, tempered glass cover can withstand more than 7J impact, filled with heat-conductive silica gel to implement high-speed heat dissipation.

Intelligent temperature control system: built-in temperature sensor real-time monitoring of the state of the lamps and lanterns, overheating automatically reduce power operation [such as a 150W explosion proof led lights case shows that the surface temperature can be controlled below 65 ℃].

Seal protection upgrade: the introduction of dual-channel labyrinth sealing structure, the protection level of IP66/IP68, effectively blocking the intrusion of water vapor and dust.

2.2 Scientific matching of power and light efficiency

According to the division of boiler room area to choose the appropriate program:

Gas boiler body area: Recommended power 150-300W, installation density of 2 / 10 square meters, illumination guidelines ≥ 500Lux, explosion-proof grade requirements Ex d IIB T4 Gb

Steam pipeline inspection channel: recommended power 70-100W, installation density of 3 / 10 square meters, illumination guidelines ≥ 300Lux, explosion-proof grade requirements Ex e II T6 Gb

Control room and power distribution area: recommended power 40-60W, installation density of 4 lamps / 10 square meters, illumination guidelines ≥ 200Lux, explosion-proof grade requirements Ex nR II T3 Gb

A gas power plant renovation project, for example, the use of 24 sets of 150W explosion-proof LED floodlights, illuminance uniformity from 0.68 to 0.92, to meet the requirements of EN 12464-1 guidelines.

3. boiler room explosion proof led lights selection five dimensions

Certification compliance: CNEx/PCEC must be issued Ex d IIB T4 certification, and labeled with the full explosion-proof mark [such as Ex d e mb IIC T6 Gb].

Optical system improvements: Wide beam [120°] lamps for inspection channels, narrow beam [60°] for precise illumination of instrument panels.

Thermal management design: die-cast aluminum housing with heat sink fins, heat sink area ≥ 800cm²/W [ensure chip junction temperature <85℃].

Emergency function integration: equipped with 180 minutes of backup power, automatically switch to emergency mode in case of power failure [brightness ≥ 50% of normal mode].

Convenience of maintenance: Quick-open structure design makes the operation of changing lamps <3 minutes, with the help of power-carrying maintenance function.

4. Industry application cases and benefit analysis

A biomass power plant boiler room renovation project

Original system problems:

The surface temperature of 400W high-pressure sodium lamp reaches 130℃, which has caused two steam pipe flash fire accidents with an annual maintenance cost of 120,000 RMB [including explosion-proof glass replacement and circuit overhaul].

Remodeling program:

Installation of 18 sets of 200W modular explosion proof led lights[Ex d IIB T6/IP66] integrated microwave induction and DALI dimming system

Comparison of results:

Annual electricity cost: 98,000 RMB before retrofitting, 32,000 RMB after retrofitting, up 67.3%.

Failure rate: 28 times/year before the retrofit, 1 time/year after the retrofit, an increase of 96.4%.

Inspection efficiency: 78% before retrofitting, 95% after retrofitting, up 21.8%.

The payback period was only 1.5 years, and ISO50001 energy management system certification was approved.

5. Technology development momentum outlook

Material innovation: Graphene composite thermal coating reduces luminaire weight by 40% and improves thermal conductivity by 300%.

Digital Twin: 3D modeling is approved to preview light spot distribution, solving the problem of blind spot inspection caused by the shadow of the boiler body.

Energy autonomy: PV+storage off-grid explosion-proof lighting system has been piloted in outdoor boilers to implement zero-carbon lighting