Raytec Improves Safety and Energy Efficiency at Gas Filling Plant

The Installation

Raytec, with its distributors at Thorne & Derrick, worked alongside Calor Gas to deliver a time-critical lighting upgrade at their Port Clarence facility which is home to a high-risk gas cylinder filling operation. The site’s filling hall, a hazardous environment requiring strict safety measures, was frequently being flagged as unfit for operation due to lighting failures. The brief was clear, replace an outdated and inefficient 400W SON system with a modern LED solution to improve safety, reduce energy costs, and meet winter-readiness timelines.

A total of 122 Raytec LED luminaires were installed across the site. This included 50 Mid Power Bay lights, 36 High Output Linears with specialised optics, and 36 Mid Power Flood lights for external and perimeter lighting.

The Challenge

The site presented multiple technical and operational challenges:

• First, the failing lighting system had become a critical safety issue making parts of the site unsafe for daily work.
• Second, the project needed to be delivered swiftly to ensure winter-readiness, when natural light would no longer offset inadequate artificial illumination.
• Third, given the proximity of residential areas, the lighting design had to avoid excessive light spill beyond the site boundaries.

The Solution

Raytec’s provided SPARTAN Mid Power Floodlights, Linears, and 50 Mid Power Bay lights. Designed for hazardous area applications, the luminaires provide uniform illumination with significantly reduced energy consumption. Raytec’s specialist optics enabled targeted light distribution, addressing concerns around spill and improving control across the site. The upgrade not only restored full operational visibility but also brought the site into alignment with energy efficiency and sustainability goals.

Support from Raytec’s lighting design service helped meet the tight project timeline, while their reliable product availability ensured zero delays during installation.

When installing a professional lighting system, we always recommend using a professional lighting design service. A professional lighting design service provides the end user and installer with a detailed report that shows the lighting levels that will be achieved on-site. This ensures there are no surprises at the point of commissioning and acts as a guide during installation, reducing installation time. A good lighting design will also offer cost savings, both by reducing the number and size of luminaires used on-site and by lowering electrical consumption. All of this should be achieved while increasing the quality of light on-site.

Raytec offers an award-winning, free-of-charge, lighting design service to all customers – bringing their installations to life. Contact a member of our team today!

Why Raytec?

Calor Gas chose Raytec for their reputation in delivering UK-built, high-performance ATEX lighting, certified for demanding hazardous environments. The products demonstrated superior optical control, substantial energy savings, and proven reliability. The flexibility of Raytec’s solutions, along with responsive local support, made us the clear choice.