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

Supplying Reliable Off-Grid Explosion-Proof Solar Lighting Systems for Remote Oil Plant Operations.

JCE Energy was awarded a significant contract to supply off-grid Ex 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 Energy's Solutions

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

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Design Stage

Design Stage

  • 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.​​​
Ex Solar Lighting System Design

Manufacture

Manufacturing

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.

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Testing

Testing

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.

Packing and Shipping

Packing and Shipping

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.

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Installation

Installation

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

Solar Powered Lighting System
Solar Powered Lighting System

Results

Results

JCE Energy 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: Minimized 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 Energy 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.