RWG Repairs and Overhaul: Explosion-Proof LED Retrofit

Voltacon retrofitted explosion-proof LED lighting across five test cells for RWG, a gas turbine repair and overhaul specialist in Coventry. RWG repairs, overhauls and tests diesel and gas-fired engines, work that involves oil and gas in hazardous conditions and demands strict adherence to safety standards.

The existing fittings were Zone 21/22 certified explosion-proof units. Rather than replace them outright, which would have meant costly re-certification, Voltacon's electricians rewired 150 metres (5 feet quoted in the original brief, corrected to the full run) of these fittings to run LED tubes, modifying each one without invalidating its certificate of safety.

A standard fitting cost £250 and the LED version £400, but Voltacon's approach brought the real cost down to a pair of LED T8 tubes at £19 plus £15 labour per fitting. This let RWG keep its existing certified fittings while switching to LED, avoiding the expense of a full re-lamp.

Lighting specification

• Explosion-proof fittings rewired: 150 metres, Zone 21/22 certified
• Tube type: LED T8
• Output: ultra-bright version at 150 lumen/watt in test cells
• Ground level illumination: over 500 lux
• Cost per fitting: £19 (pair of tubes) plus £15 labour
• Standard fitting cost: £250; LED version: £400

The volatile materials present in RWG's test cells carry a serious risk of fire and explosion, which is why the fittings needed to remain certified throughout the upgrade. Using LED T8 tubes also cut ongoing maintenance costs. The result was a brighter, safer working environment for RWG's gas turbine repair and overhaul operation, delivered without the expense of replacing the explosion-proof fittings themselves.

Products used in this project

Solar Panel Z Bracket Mounting Kit 4pcs £7.29 inc VAT £6.08 exc VAT Adjustable Tilt Solar Panel Mounting Kit £29.40 inc VAT £24.50 exc VAT Adjustable Flat Roof & Ground Solar Panel Mounting Kit 15-35° £72.45 inc VAT £60.38 exc VAT Copper Cable Lugs 25mm² to 95mm² M10 £0.62 inc VAT £0.52 exc VAT

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