Explosion-proof lighting is not a one-size-fits-all solution. The lighting fixture that performs well in an onshore refinery may not be the best choice for an offshore platform, where salt spray, humidity, vibration and constant exposure to harsh marine conditions can place additional stress on the equipment.
Both offshore and onshore facilities may contain hazardous or classified areas where appropriately certified Ex lighting is required. However, the environmental conditions at each location can be very different.
Choosing the right explosion-proof light is therefore not only about hazardous-area certification. Housing material, IP rating, temperature resistance, mounting requirements and fixture type can all affect reliability, maintenance requirements and service life.
For industrial and oil & gas projects, understanding these differences helps engineers and procurement teams select lighting that is suitable for the actual operating environment.
Why the Installation Environment Matters
Hazardous-area classifications such as Zone 1, Zone 2, Zone 21 and Zone 22 help determine the required level of protection against potentially explosive atmospheres. However, the zone classification does not by itself determine how well a fixture will withstand the surrounding environmental conditions.
Offshore platforms and marine facilities can experience:
- Salt-laden air and salt spray
- High humidity and moisture
- Wind and water exposure
- Continuous equipment vibration
- Temperature fluctuations
- Mechanical stress
Onshore refineries, tank farms and petrochemical facilities may face:
- High ambient temperatures
- Intense UV exposure
- Dust and sand
- Process-related chemicals
- Outdoor weather conditions
- Large-area lighting requirements
This is why an explosion-proof light should be selected according to both the hazardous-area classification and the physical environment where it will be installed.
Explosion-Proof Lighting for Offshore and Marine Facilities
Corrosion Resistance Is a Major Consideration
Offshore lighting fixtures are continuously exposed to moisture and salt-laden air. Over time, unsuitable materials can be affected by corrosion, potentially increasing maintenance requirements and reducing service life.
Depending on the application, marine and offshore Ex lighting may use:
- Copper-free aluminium with protective coatings
- 316L stainless steel
- Other corrosion-resistant materials designed for demanding environments
316L stainless steel can be particularly suitable for applications where resistance to chloride-related corrosion is important.
Marine-grade explosion-proof LED fixtures are designed for demanding environments where moisture, corrosion, vibration and changing weather conditions need to be considered during equipment selection.
Vibration and Mechanical Stress
Offshore facilities contain pumps, compressors, generators and other equipment that can produce continuous vibration. Platform movement and other operational activities can also place mechanical stress on lighting fixtures and mounting systems.
For these installations, the fixture and mounting arrangement should be suitable for the expected vibration and mechanical conditions.
A light being Ex certified does not automatically mean it is suitable for every offshore application. Its mechanical construction, mounting system and environmental specifications should also be reviewed.
IP Rating and Water Protection
Water and dust protection are important considerations for offshore lighting.
Depending on the application, IP66 or IP67 protection may be required to help protect the enclosure against dust and water ingress.
Sealed housings and durable lenses or diffusers can provide additional protection in areas exposed to weather, washdowns and demanding maintenance conditions.
Typical Offshore Applications
Explosion-proof lighting can be used in:
- Offshore platform decks
- Walkways and access routes
- Helidecks and evacuation routes
- Process modules and skids
- Control rooms
- Offshore living quarters
- Marine loading areas
- Jetties and terminals
Explosion-Proof Lighting for Onshore Refineries and Tank Farms
Heat and UV Stability
High ambient temperatures can affect LED performance, electronic components and overall fixture life if the equipment is not designed for the operating conditions.
UV exposure can also affect certain materials, lenses and external components over extended periods.
For outdoor installations, it is important to check the fixture's operating temperature range, thermal management and UV resistance before selecting the equipment.
Choosing the Right Housing Material
Onshore facilities can provide greater flexibility in housing material selection because continuous exposure to marine salt is generally less severe than on offshore installations.
Depending on the application, suitable options may include:
- SS304 or SS316L stainless steel for demanding process environments
- FRP or GRP for corrosion-resistant and lightweight applications
- Galvanized steel for certain structural and pole-mounted applications
- Copper-free aluminium with suitable protective coatings
The appropriate material should be selected according to the site's environmental conditions and project specifications.
Lighting Large Industrial Areas
Refineries, tank farms, warehouses and process plants often require lighting over large areas.
Common explosion-proof lighting solutions include:
- Ex high bay lights
- Ex low bay lights
- Ex flood lights
- Ex linear luminaires
- Pole-mounted lighting
- Ex bulkhead lights
Selecting the right fixture is not simply about choosing the highest lumen output. Mounting height, beam distribution, spacing and the layout of the facility should also be considered to provide suitable and uniform illumination.
Offshore vs Onshore Explosion-Proof Lighting
| Factor | Offshore / Marine | Onshore Refinery / Tank Farm |
|---|---|---|
| Main environmental concerns | Salt, moisture, corrosion and vibration | Heat, UV, dust and chemicals |
| Common housing materials | Copper-free aluminium, 316L stainless steel | FRP/GRP, stainless steel, galvanized steel, aluminium |
| IP protection | Often IP66/IP67 depending on application | Selected according to site conditions |
| Mounting | Vibration-resistant and reinforced | Structural, pole-mounted or equipment-specific |
| Common fixture types | Marine-grade LED, bulkhead, floodlight, portable | High bay, low bay, floodlight, linear |
| Emergency lighting | Important for evacuation and safety routes | Depends on facility and safety requirements |
Ex Lighting Solutions for Both Offshore and Onshore Applications
Some explosion-proof lighting categories can be used in both environments when the correct product specification is selected.
Ex Flood Lights
Ex flood lights can provide wide-area illumination for tank farms, process areas, platform decks, loading areas and outdoor work zones. The housing and corrosion protection should be selected according to the installation environment.
Ex High Bay and Low Bay Lights
High bay and low bay Ex lighting systems can provide efficient illumination in industrial buildings, process areas, warehouses and other facilities where high mounting heights or broad coverage are required.
Ex Linear Luminaires
Ex linear lighting can provide continuous and uniform illumination in industrial areas, process facilities, corridors and other applications requiring elongated light distribution.
Ex Marine-Grade Fixtures
Marine-grade Ex lighting is designed for applications where corrosion, moisture and harsh marine conditions are major considerations.
Ex Panel Lights
Ex panel lights can be used for localized illumination in control panels, instrument enclosures and industrial equipment.
Ex Emergency Exit Lights
Emergency exit and escape-route lighting can help provide visibility during emergency situations in areas where safe evacuation is critical.
Ex Portable Lights
Portable explosion-proof lights can be useful for inspection, maintenance and service activities in hazardous areas where temporary or localized lighting is required.
Ex Bulkhead Lights
Ex bulkhead fixtures can provide robust illumination for walkways, corridors, access areas and other industrial locations.
How to Select the Right Explosion-Proof Light
The important point is that Ex certification alone does not automatically make a lighting fixture suitable for every environment. The certification addresses explosion protection, while factors such as housing material, IP rating, temperature range and mechanical construction determine whether the product is appropriate for the specific installation.
Before finalizing an explosion-proof lighting specification, consider the following:
1. Confirm the Hazardous-Area Classification
Identify whether the installation is classified as Zone 1, Zone 2, Zone 21 or Zone 22, or another applicable classification.
2. Evaluate the Environmental Conditions
Consider exposure to:
- Salt and moisture
- Water and washdowns
- Dust and sand
- High temperatures
- UV radiation
- Chemicals
- Vibration
- Mechanical impact
3. Select the Appropriate Housing Material
The housing should be capable of withstanding the environmental conditions expected throughout the intended service life of the fixture.
4. Check the IP Rating
Select an IP rating appropriate for the actual level of dust and water exposure at the installation location.
5. Consider Lighting Performance
Review lumen output, beam angle, mounting height, spacing and required illumination levels before choosing the fixture.
6. Verify Certification Requirements
Depending on the project and applicable regulations, certification requirements may include ATEX, IECEx, UL/CSA, EAC Ex or other relevant standards.
Always verify the actual product certificate and Ex marking for the specific fixture rather than relying only on a general "explosion-proof" description.
Explosion-Proof Lighting Solutions from Power Electrical Trading LLC
Power Electrical Trading LLC supplies ATEX and IECEx certified explosion-proof lighting solutions in Abu Dhabi, UAE, designed for hazardous and classified industrial environments.
Our product range includes:
- Ex flood lights
- Ex high bay lights
- Ex low bay lighting systems
- Ex linear luminaires
- Ex marine-grade fixtures
- Ex panel lights
- Ex emergency exit lights
- Ex portable lights
- Ex bulkhead lights
These solutions are available for applications requiring suitable protection for Zone 1, Zone 2, Zone 21 and Zone 22 environments.
For oil & gas, petrochemical, refinery, industrial and marine projects, our team can help identify suitable Ex lighting solutions based on the hazardous-area classification, environmental conditions and project requirements.
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