Class 1 Div 2 LED Lighting

TheLightingCenter offers Class 1 Div 2 LED lighting that's designed to remain safe in hazardous environments.

Our class 1 div 2 LED lighting products have been designed and built to be used safety in the presence of hydrogen, acetylene and other petrochemicals. Commonly our Class 1 Div 2 lighting LED are used in petrochemical tanks, boat yards & marine applications, plants, oil rigs, and more.  Our Class 1 Div 2 LED lights not only run safely in these dangerous environments, but they also reduce energy costs and improve safety through high quality light output. 

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Class 1 Div 2 LED Lighting

Class 1 Division 2 lighting fixtures are usually installed in environments classified as hazardous. Such locations have harmful materials or potentially ignitable or explosive substances that if subjected to certain external conditions can undergo a chain reaction that will cause an explosion. Hazardous locations require sturdy and safe lighting solutions because some are located in inaccessible remote areas. If disaster strikes in these areas, there can be terrible consequences for the workers.

In 2016, there were 89 accidents resulting in death in the quarrying and mining industry and 318 others in the manufacturing industry -- in the U.S. alone. The U.S. Department of Labor is therefore very concerned about using the appropriate equipment in hazardous locations to minimize accidents and fatalities.

In hazardous applications, inappropriate or faulty electrical equipment can be the cause of explosions. The lighting fixtures used in these areas must have special wiring and other safety features to prevent such incidents.

Examples of class 1 division 2 locations include:

LED Refinery Lighting

Z

Oil and Gas Plants

Z

Chemical Processing Plants

Z

Aircraft Hangars

Z

Paint Spray Booths

Z

Enclosed Fueling Stations

Z

Grain Silos

Z

Food Processing Facilities

The Hazardous Location Classification System

In North America, the system of classification for these areas was designed by the National Fire Protection Association, also known as the NFPA. This system is applied together with the National Electric Code, or NEC. The two systems describe the types of hazardous substances that if present in the air in sufficient quantities are capable of producing explosions.

The NFPA 70 categorizes these areas into Classes, Divisions, and Zones. The classifications assist business owners in purchasing the appropriate light fixtures and help them to adhere to safe installation practices.

The Occupational Safety and Health Administration uses the NEC hazardous location classification system to enforce laws and regulations governing the installations for these locations.

 

Definition of Class 1 Division 2 Hazardous Locations

An area is usually classified as a Class 1 Div 2 location because of:

The presence of flammable gases or volatile liquids being processed, used, or handled but in confinement -- in closed systems or containers. These flammable, volatile liquids or gases can pose a safety threat if they escape from this confinement if a container or system breaks down or accidentally ruptures.

Ignitable amounts of vapors or gases that could pose a hazard if the mechanical ventilation equipment that keeps safety in check fails.

If it is close to a Class 1 Division 1 location which could transfer ignitable or explosive vapors or gases that can become a hazard in the area if the clean air ventilation features malfunction or fail.

For lighting products to qualify for OSHA's hazardous location approval, they must have the appropriate temperature range and group and class markings. OSHA uses the following group definition classifications set by the NEC code.

GroupThreat Maximum Experimental Safe Gap or MESG Value RequiredMinimum Igniting Current Ratio or MIC Ratio Required
AAcetylene  
BFlammable or combustible gas or liquid produced vapor that if mixed with air will explode or burn, such as hydrogenAt least 0.45mmAt least 0.40
CFlammable or combustible gas or liquid produced vapor that if mixed with air will explode or burn, such as Ethylene0.45mm to 0.75mm0.40 to 0.80
DFlammable or combustible gas or liquid produced vapor that if mixed with air will explode or burn, such as PropaneAt least 0.75mmGreater than 0.80
EMetal dust that is combustible in nature from commercial alloys, magnesium, aluminum, or any other dusts whose conductivity, particle size, and abrasiveness can be a cause of electrical equipment hazard  
FCombustible dust from carbon that has at least 8% entrapped volatiles such as charcoal, carbon black, coke, or coal dust  
GAll other types of combustible dust outside groups E and F that include grain, flour, chemicals, wood or flour dusts.  

 

Explosion Proof Vs. Intrinsically Safe Class 1 Div 2 Led Lights

Applications such as petrochemical storage tanks, grain silos, power plants, tank farms, vehicle spray booths, and fuel tanks require adequate lighting for safe working conditions. High-quality light helps the workers in these areas to remain productive and alert. Electricity and volatile gases and vapors are a dangerous mix. Electrical systems may produce sparks as part of their working mechanism or can produce flames or sparks unexpectedly. This is why lights installed in hazardous locations have to prevent ignition of flammable gases and vapors.

While explosion proof lights have flame paths that cool down hot gases and prevent ignition, intrinsically safe lights prevent explosions in hazardous areas through another safety mechanism. The lights rely on a technique that is based on restricting energy, both thermal and electrical, to an intensity lower than what’s required to kindle a specific hazardous atmospheric mixture.

Intrinsically safe lights are mostly battery powered and their current is so low that the production of sparks or the generation of thermal energy is hindered. Explosion proof lighting and intrinsically safe lighting are not interchangeable, but each has its own benefits.

Explosion proof lights are not necessarily watertight or airtight unless it’s specified. They should not be submerged in liquids or exposed to high amounts of liquids, unless they are certified as vapor tight lights. Vapor tight lights are also not equal to explosion proof lights. Light fixtures can be designed to keep out the ingress of water or dust but not contain an explosion. Class 1 Div 2 LED lights must be appropriately rated and marked as safe for use in those environments.

 

Why You Should Switch From HIDs to LED Class 1 Division 2 Lights

  • HID hazardous location lights have been around for years. In fact, most Class 1 Division 2 hazardous locations previously used metal halide lamps with high wattages for illumination. But HID lamps have ballasts, bulbs, produce a high amount of heat, and require warm-up before they can produce enough light. LED lamps, however, have no ballasts or bulbs and generate instant light.
  • Metal halide explosion proof lights depend on an electric arc for light generation. They have metal halides and mercury vapor to intensify the light generated in the arc tube. When switched on, these lamps produce a bluish color, and as their pressure and heat increase, the light turns to white. The major disadvantage of this process is that at least 75% of the energy generated is heat energy. It is only a paltry 25% that is emitted as light. A MH Class 1 Division 2 lamp is very inefficient and can be a safety hazard in volatile conditions.
  • A HID light takes a very long time to attain 90% light output, and when it gets to this point, the light cannot be dimmed or adjusted without the bulb getting damaged. These lamps do not easily work with light control systems that can help save energy. LED lights, on the contrary, have a wide dimming range and work excellently with many light control features such as dimmers, motion sensors, and daylight sensors.
  • Metal halide lamps have a maximum rated life of 15,000 hours. The minimum lifespan of LED lights is 50,000 hours. If you install LED lamps, you’ll spend less on replacement lamps and lighting maintenance. Your application will also not experience extended downtimes caused by burnt out bulbs or frequent lamp replacement.
  • Metal halide lamps are very reliant on ballasts, and ballasts have even shorter lifespans than the lamps. They also draw a small percentage of the electricity the lamps pull, driving up energy costs. Metal halides experience a color shift as they age. Their light turns to a pink color, which makes visibility almost impossible. When they shift color, they only produce a measly 40% of their initial light output while utilizing the same amount of energy. The longer these lights are in use, the higher the costs of running them. Their ballasts and capacitors need constant changing to keep them in good working order.
  • LED lamps are designed to direct their light where it is required; they are directional. Older lamp types are multidirectional. They need reflectors to reduce light wastage, which results in lumen loss because the reflection process is never 100% accurate.
  • LED lamps also have high CRI values of above 80 which give their light a bright, daylight quality. Some can be tuned to different CCTs to illuminate different tasks.

There are multiple benefits of retrofitting HID and fluorescent Class 1 Division 2 fixtures with LED lighting. Besides the safety they offer, which is paramount in hazardous locations, LED lights have excellent light quality and high energy efficiency.

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