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Hazardous location lighting refers to fixtures that you can safely use in an area where it&#;s likely that fire might start. According to the National Electrical Code, hazardous locations are those areas &#;where fire or explosion hazards may exist due to flammable gases or vapors, flammable liquids, combustible dust, or ignitable fibers or flyings.&#; A substantial part of the NEC is devoted to the discussion of hazardous locations, as electrical equipment, including lighting fixtures can become a source of ignition in these volatile areas. These locations may include chemical plants, laboratories, oil and gas refineries, mining operations, and other industrial sites that contain extreme temperatures, combustible materials, and corrosive liquids or vapors.
Given that light fixtures are electrical devices, they pose a risk in locations where sparks may ignite flammable gases and other materials. Explosion proof lighting is an important component for safety where these conditions exist. Installed light fixtures that are not suited for these hazardous locations may result to a catastrophic situation.
is a term that can be used interchangeably with explosion proof lighting. Explosion proof light fixtures are able to contain sparks that could potentially ignite the flammable and explosive gases in the atmosphere. This means they have the capacity to prevent external explosions from occurring in a hazardous location. Installing explosion proof lighting significantly reduces the risk of explosions by preventing the ignition of flammable gases and vapors.
To determine a hazardous area, it is rarely possible by simple examination of a plant or a plant design, without extensive experience to decide the areas that are hazardous. Detailed information is important and this involves the analysis of the basic properties of the materials present and the possibility of a release occurring.
Hazardous areas classifications divide areas into zones based on the likely frequency and duration of a release, release rate, concentration, velocity and ventilation of the area. Classification also considers the materials being used and assigns an equipment group and temperature classification to the area based on the material properties.
Different gases require different amount of energy to ignite. The concept of gas grouping and temperature classification is used to classify electrical apparatus according to its suitability for use with explosive atmospheres or particular gases.
Hazardous areas classification may be carried out by direct analogy with typical installations described in established codes. Classification ofis based on classes, divisions and groups. With the Class System, you divide the materials by type. There are three different classes as defined by the NFPA 70, NEC, and CEC: Class 1, Class II, and Class III.
Class I
includes combustible vapors that are liquid-produced, and flammable gases. E.g. gasoline storage areas, petroleum refineries, spray finishing areas and fuel servicing areas among others.Class II
includes combustible dustsClass III
includes ignitable flyings and fibers. E.g. textile mills, cotton seed mills or flying plants.When it comes to hazardous location divisions, there are two types: Division 1 and Division 2. The Divisions defines the likelihood of the hazardous material being present in a flammable concentration.
Division
Definitions
Division 1- In which ignitable concentrations of hazards exists under normal operation conditions and/or where hazard is caused by frequent maintenance or repair work or equipment failure
Division 2- In which ignitable concentrations of hazards are handled, processed or used, but which are normally in closed containers or closed systems from which they can only escape through accidental rupture or breakdown of such container or system.
What is class 1 div 2?
Class 1 Hazardous locations refer to the facilities which deal with flammable vapors, gases and liquids. Division 2 specifies that these flammable materials are handled, processed or used in the defined hazardous location, but are not normally present in concentrations high enough to be ignitable. In other words, it requires proper handling and storage of the flammable gases, liquids or vapors to prevent such an ignition under normal operating conditions.
What is class 2 div 1?
Class 2 locations consists of locations where combustible dusts may exist that have the potential to become flammable or ignitable. They include such locations as flour and feed mills, grain elevators, coal plants and metal powder manufacturers among others. Division 1 is a subset of class 2 and is classified as an area where the explosive or flammable combustible dusts mentioned above can exist under normal, everyday operating conditions.
These are locations which handle materials and commodities with a high risk for ignition causing fires or explosions. The main purpose for the code requirements is to facilitate the proper selection and installation of apparatus to be used safely in the different environments, considering the properties of the flammable materials that will be present.
is that they are there to protect the employees and visitors at that location.
Lighting for hazardous locations are often termed as Hazloc lights and are designed to minimize the risk of explosions caused by any sparks within its housing or any other accidental events. Such lighting fixtures are explosion-proof, and are meant to ensure overall well-being of not just workers, but the facility as well. When you add LED into the mix, it ensures you save on energy costs without compromising on safety. Hazardous LED lighting fixtures are put through rigorous tests and safety procedures and are certified before being sold for use. Here are some of the common types of hazardous LED lights available for different lighting requirements.
High Bay LEDs are for illuminating spaces with high ceilings. Such fixtures are perfect for units in hazardous locations as they allow for clear visibility through even light distribution. The placement of such LED fixtures make them ideal for commercial and industrial use in areas like marine, ocean, aerospace fields, pumping stations or any other spaces with high humidity, high temperatures, or high dust environments.
These are lights used to illuminate outdoor spaces. Hazloc(short for hazardous location) LED outdoor area lights are designed to be explosion-proof, and can be used for optimum illumination of areas such as oil refineries and gas stations, oil and gasoline loading docks, distilleries, and other hazardous outdoor locations.
They are designed to be vapor-proof meaning, these fixtures are sealed and gasketed. These fixtures are appropriate for use in damp areas like oil and gas and chemicals. They can also be applied in flour and fine particles production and storage facilities, high dust, high temperatures, and high vapor locations.
LED emergency exit signs are appropriate for hazardous locations, especially those that have a presence of flammable vapors or gases, or combustible dust. It provides distinct, highly visible exit marking to indicate safe egress areas during power outages and other emergencies. Some common applications areas are manufacturing and chemical plants, paint shops, oil refineries, gas stations, industrial facilities, warehouses and other Class 1, division 2 hazardous locations.
These are small, yet significant addition to Hazloc lighting. Such luminaires are best for task or general illumination in small and confined spaces and can be used in Class 1, II, and III hazardous locations like chemical plants, manufacturing plants, oil refineries and processing plants.
Want more information on explosion proof materials? Feel free to contact us.
Almost all theused in the hazardous locations are flood mounted. Flood Mount brackets, similar to yoke or trunnion brackets allow the light fixtures to be affixed to a flat surface, such as a wall, roof soffit or a square pole. It comes with pre drilled holes to allow for easy mounting and installation. Others, like the high bay lights are suspended from the ceiling with hooks and rings.
Explosion-proof design-the standard LED lighting fixtures are engineered in a way that exposes the wiring, bulb, switches and contacts to the external atmosphere. In such cases, a spark from a loose contact, heat from the bulb or movement of the switch is sufficient to ignite and lead to a flammable environment. With the explosion-proof LEDs used in hazardous lighting, the fixture components are encased to prevent potential sparks or flames from escaping the internal housing.
Durable and tough-the explosion-proof LED light fixtures have a rugged build with sturdier materials that offer a high degree of durability compared to the standard lighting fixtures. They are designed to withstand the harsh working environments which makes them a better choice for operators. It reduces the refurbishing and maintenance costs.
Allow greater mobility-explosion-proof LED lights are designed and engineered with thicker tempered glass lenses and a sturdy frame, making them highly resistant to vibrations. As such, the durable design allows for convenient transportation of the fixtures from place to place by forklifts or other machines without the risk of malfunction or damage. It is, therefore, easy to move them around, which makes them the perfect choice for operators who require mobile illumination.
High-efficiency- these explosion-proof HazLoc LED lights are extremely energy efficient. They put to use more than 90% of the energy to produce light and have near-zero heat or conversion loss. This translates to less power used for functioning which significantly reduces the utility bills.
Lighting that isn&#;t designed for use in a hazardous location opens up the company to a number of risks and potential costs.
Health and Safety: the biggest risk is that of explosion or fire. Fortunately, the HazLoc LED lights have fewer components that can ignite or cause a fire when exposed to flammable gases or vapors. When there is a fire in the lighting, it typically starts within the conduit system and especially the old lighting system which may have issues with moisture condensation. Arching or shorting within the conduit system instantly transmits all the way down the line to the fixture. Explosions or fires from the wrong fixtures, switches and conduits can cause catastrophic damage to people and property.
Non-compliance fines: facilities non-compliant with standards risk getting stiff fines, which is just the beginning. In case the wrong fixtures are installed, they will have to be replaced with ones that meet the code. In HazLoc lighting, the fixtures must comply with NFPA, OSHA, or CEC/NEC standards by law. If caught with non-compliant lights in hazardous locations, the company may be subjected to lawsuits which could become very expensive.
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Going about selecting and narrowing down the best ex-proof junction box for your business can be a tedious and complicated process and we are here to help. There are no tell-tale signs that can possibly indicate the quality of an explosion proof junction box just by visually looking at it and it can be confusing for new buyers such as yourself, to recognise the best ex-proof junction box immediately.
Fret not, we are here to make your life easier with the following guide.
Here are 8 guidelines to follow that will help you streamline your entire buying process and ensure you get the most bang for your buck.
Firstly, having a clear understanding of your business will help you to narrow down and speed up your search. Determining which zone your business operates under will allow you to direct your search focus towards the appropriate ex-proof junction boxes. This makes your selection process easier as you do not have to consider ex-proof junction boxes that do not meet your zone requirements.
For example, if your business operates in zones 0 and 1, then you should most likely purchase ex proof junction boxes that are Ex &#;d&#; certified. On the other hand, if your business mainly operates under zone 2 conditions, then junction boxes that are Ex &#;e&#; certified would suffice. This will be further explained in detail below.
There are a total of 3 zones used to classify each type of hazardous area. Zone 0 is used to describe an area that is under the constant exposure of combustible gas. Zone 1 refers to an area that might get exposed to explosive gas under normal operations while zone 2 is classified as an area that is highly unlikely to contain any explosive gas. Therefore, understanding your business and its operations well can lead to an accelerated search process, saving valuable time and resources for both you and your company.
Ex &#;d&#; junction boxes are also known as flameproof junction boxes. Ex &#;d&#; or flameproof means that the junction box must be constructed according to the &#;flameproof&#; standard. Flameproof junction boxes have the ability to contain any explosions from within its enclosure while any escaping sparks or flames will be cooled by the &#;flame path&#;, which mitigates any risk of causing the explosive gas atmosphere in the area to ignite further and cause any further damage.
On the other hand, Ex &#;e&#; junction boxes are constructed according to the &#;increased safety&#; standard. This means that Ex &#;e&#; junction boxes are built to never produce any current flow, sparks or temperatures that have the potential to ignite the explosive atmosphere around the junction box. Thus, Ex &#;e&#; junction boxes are considered explosion proof but are not certified as flameproof.
Ex &#;d&#; junction boxes are usually constructed from die cast iron or steel and can operate in places that are exposed to high temperatures such as underground coal mines. Alternatively, Ex &#;e&#; junction boxes are normally made from engineered plastic and generally more suited for surface applications and environments with lower surrounding temperatures.
Both Ex &#;d&#; and Ex &#;e&#; junction boxes can operate in zone 1 and 2 areas. However, only Ex &#;d&#; junction boxes can withstand and contain internal explosions. Therefore, it is fair to say that Ex &#;d&#; junction boxes offer a greater level of protection compared to Ex &#;e&#; junction boxes.
We understand that customers can get confused regarding the different levels of protection that an ex-proof junction box may offer. Therefore, all of Supermec&#;s ex-proof junction boxes on our ecommerce platform are labelled clearly. Customers using our ecommerce platform will be able to identify the level of protection for each ex-proof junction box that suits their needs quickly and easily.
For a junction box to be certified as ex-proof, the junction box has to be accompanied with an ATEX or IECEX certificate. This certification shows that the junction box has undergone many rounds of stringent checks in order to finally be certified as explosion proof. A junction box without an ATEX or IECEX certificate can put your entire business in danger if an explosion were to occur in the workplace. Therefore, it is of extremely high priority for you to ensure that the junction box has been officially certified as explosion proof by the above mentioned certification bodies.
As Ex &#;d&#; junction boxes offer greater protection, they are more expensive in general as compared to Ex &#;e&#; junction boxes. This is because the materials used to construct Ex &#;d&#; junction boxes often have to be die-casted, which can be a costly process. Therefore, if you are on a tighter budget, then perhaps buying Ex &#;e&#; junction boxes would be a more feasible option for your business.
Planning your budget in advance also allows you to be in a better position to make bulk purchases, which may often lead to a small discount from the manufacturer/supplier.
You would be surprised at how the raw materials can affect the quality of the finished product. Research has shown that product parts made in Europe are of a higher quality than parts that come from China. Therefore, the end product made from parts of higher quality would definitely be of higher performance standards as well.
As such, you should take into consideration the source of the materials used to build the junction box. If the components that are used to construct the junction box come from Europe, you can trust that the manufacturer prioritises quality and safety of its junction boxes. Supermec imports all our product parts from Europe while the assembly of the junction boxes is carried out in Singapore, where our headquarters is located.
You could get into trouble with the law should you purchase a junction box that doesn&#;t come with the necessary certifications and should always ensure that the product that you are using has been certified for proper use within your area of operations.
Contacting the sales team or production team of the manufacturer directly is a fast and efficient way for you to clarify your doubts. By speaking directly to the employees, you will be able to judge their expertise and knowledge in junction boxes for yourself. Doing this makes it easier to sieve out manufacturers and suppliers with an inexperienced or unprofessional sales team.
Just reach out to us at and our professional and customer focused sales team would be able to address your concerns immediately.
Lastly, it might be a good idea to conduct a quick background check or audit on the company that you are buying the ex-proof junction box from to ensure you are buying a well-established and good quality product.
Here are some things to look out for during the check:
As mentioned above, ATEX/IECEx certificates are required for all ex-proof products. Therefore, you should check that the company has the necessary certifications shown on their website or alongside their different product listings.
Companies that have been in the industry for a longer period tend to have more experience. Therefore, they are also more likely to provide better quality ex-proof junction boxes thanks to their accumulated knowledge on the industry norms and standards over time.
When a company has an extensive clientele base, it is a sign of its professionalism and competence. It is advisable to engage a company that has worked with a large network of clients and partners as it shows that its services and products have been approved and used by other companies before.
Lastly, awards are the most obvious signs of how established a company is. Therefore, a company that has won various awards/accolades would most likely meet your business needs as compared to a company that has not won any awards. You can view the various awards that Supermec has won from our press releases.
Summary
Ultimately, the responsibility of buying the best ex-proof junction box for your business lies with you to do the necessary research before reaching a final decision. However, it is always a plus point when the manufacturer simplifies the buying process by making information easily accessible for you.
As the leading manufacturer of explosion proof junction boxes in Singapore, Supermec wants to help our customers save time and money by making the buying process as simple as possible. We hope that after reading this guide, you will learn what to look out for in buying the best explosion proof junction box for your business.
Contact our friendly sales team at or you can drop us a call at +65 to find out more about our explosion proof solutions. Alternatively, you can visit our ecommerce platform where you can browse through the complete range of explosion proof products for various hazardous areas at your own time.
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