Off-Grid Ex Solar Lighting Systems for a Processing & Distribution Oil Plant in the Middle East

JCE was awarded a significant contract to supply Off-Grid ATEX / IECEx Solar Lighting Systems for a remote oil processing and distribution plant in the Middle East. The explosion-proof solar power systems provide lighting and security within hazardous areas of the plant, delivering significant cost savings, operational efficiency, and environmental benefits.

Customer’s Challenge:

The oil processing and distribution plant is located in a remote region of the Middle East, where there is no existing infrastructure to power the lighting around the facility perimeter. This posed a significant challenge for ensuring adequate lighting and security in hazardous areas without relying on grid power.

Project Requirements:

The client required an off-grid lighting solution that could:

• Provide reliable lighting and security for hazardous areas.
• Operate independently of grid power due to the remote location.
• Minimise installation infrastructure costs.
• Reduce long-term operational expenses.
• Lower carbon emissions and support sustainability goals.

JCE’s Solutions:

JCE addressed these requirements through a comprehensive process involving design, manufacturing, testing, and shipping:

• Energy Analysis and Optimisation: Conducted detailed energy analysis to maximise efficiency.
• Load Analysis: Assessed energy demands to determine system requirements.
• Energy System Simulation: Simulated system performance under various conditions.
• Control System Philosophy: Developed control strategies to ensure seamless operation.
• Enclosure and Bracket Design: Custom-designed enclosures and brackets for safe component housing and support.
• Electrical Calculations and Schematics: Prepared precise calculations and detailed schematics to guide manufacturing and installation.

With the design finalised, manufacturing of the explosion-proof solar technology systems commenced.

Each system is compliant with ATEX / IECEx, Zone 2 standards and includes:

• ATEX Certified Solar Panels: Ex ec mc 365W, 31V, Photovolatic Solar Panel
• Ex d 15A, Solar Charge Controller Enclosure
• Ex ec 120Ah 24Vdc, Battery Enclosure
• Ex d Battery Isolator Enclosure
• Ex d Photocell Enclosure

The production of components was meticulously planned to align with lead times and the client’s delivery schedule.

Before shipment, rigorous Factory Acceptance Testing ensured system functionality and quality:

• Equipment Functionality Testing: Ensured all components operated correctly.
• HMI Programming and Testing: Verified human-machine interface configurations.
• Alarms and Communication Testing: Ensured reliable communication and alarm systems.
• Remote Communication Testing: Validated remote communication capabilities, both onshore and offshore.
• Battery Charging and Discharging Tests: Confirmed the reliability and efficiency of battery systems.

Adhering to strict packing procedures ensured the safe transport of all components:

• Solar Panels: Packed in foam-lined crates, compliant with BS 1133 Section 8.
• Ex d Control Systems: Crated in compliance with BS 1133 Section 8.
• Batteries: Manufactured to mitigate hazardous risks during air freight.
• Shipping Preparation: All items prepped and loaded efficiently to facilitate client shipping.

The systems were engineered to optimise space and minimise installation efforts, resulting in a compact design that facilitated easy installation.

JCE successfully delivered a reliable and sustainable off-grid lighting solution tailored to the remote location of the oil processing and distribution plant.

The benefits include:

• Cost Savings: Significant reductions in installation infrastructure costs.
• Operational Efficiency: Minimised long-term operational expenses due to the system’s efficiency and reliability.
• Environmental Impact: Decreased reliance on grid power and lowered carbon emissions, supporting the client’s sustainability goals.
• Optimal Solution for Remote Location: Intrinsically safe solar power provided a practical and effective solution for powering the facility’s perimeter lighting, overcoming the challenges posed by the absence of existing infrastructure.

By leveraging their expertise in explosion-proof solar power, JCE has enhanced the safety and security of the plant, ensuring continuous and reliable operation in a challenging environment. The use of the ATEX/IECEx certified solar energy systems ensures compliance with safety standards, making it a robust solution for hazardous locations.