Thorne & Derrick Improve Safety and Energy Efficiency at Gas Filling Plant
Published 01 Aug 2025
The Installation
Thorne & Derrick, in partnership with Raytec, worked alongside Calor Gas to deliver a time-critical lighting upgrade at their Port Clarence facility, home to a high-risk gas cylinder filling operation.
The site’s filling hall is a hazardous environment requiring strict safety measures. Frequent lighting failures had led to it being flagged as unfit for operation. The brief was clear: replace an outdated and inefficient 400W SON system with a modern LED solution to improve safety, reduce energy costs, and meet winter-readiness timelines.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, including 50 Mid Power Bay lights, 36 High Output Linears with specialised optics, and 36 Mid Power Flood lights for external and perimeter lighting.
Project Overview:
- Client: Calor Gas
- Location: Port Clarence Gas Filling Facility
- Challenge: Failing SON lighting system in hazardous area
- Solution: 122 Raytec ATEX LED luminaires supplied by Thorne & Derrick
- Outcome: Improved safety, full operational visibility, and energy savings
The Challenge
- The failing lighting system had become a critical safety issue, making parts of the site unsafe for daily work
- The project needed swift delivery to ensure winter-readiness, when natural light would no longer offset inadequate artificial illumination
- Given the proximity of residential areas, the lighting design had to avoid excessive light spill beyond site boundaries
The Solution
Raytec provided SPARTAN Mid Power Floodlights, Linears, and 50 Mid Power Bay lights. Designed for hazardous area lighting applications, the luminaires deliver uniform illumination with significantly reduced energy consumption.
Raytec’s specialist optics enabled targeted light distribution, addressing spill concerns and improving control across the site. The upgrade not only restored full operational visibility but also aligned the site 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.
We always recommend using a professional lighting design service when installing a lighting system. It provides a detailed report on expected lighting levels, ensures faster commissioning, reduces surprises during installation, and can cut both equipment and energy costs while improving lighting quality.
Raytec offers an award-winning, free-of-charge lighting design service to all customers – bringing installations to life.
Why Raytec?
Calor Gas selected Raytec for their reputation in delivering UK-built, high-performance ATEX lighting for hazardous environments. Their products demonstrated superior optical control, substantial energy savings, and proven reliability. The flexibility of Raytec’s solutions, combined with responsive local support, made them the clear choice.
“Raytec’s LED lighting has significantly improved safety and visibility within our facility, particularly within the filling hall where the majority of fittings had failed. The new lighting system has not only restored full operational visibility but also delivered measurable energy savings, aligning with our sustainability goals. The flexibility of the optics helped us control light spill in sensitive perimeter areas. Thorne & Derrick’s support throughout—from site surveys and technical advice to post-installation support—was invaluable in ensuring the project was delivered on time and to a high standard.”
– Calor Gas
Partner with Thorne & Derrick
Partner with Thorne & Derrick for your next lighting upgrade. We provide technical expertise, site surveys, and reliable supply of Raytec hazardous area lighting.
About Raytec
Raytec is a global leader in LED lighting for hazardous areas, providing ATEX and IECEx-certified solutions designed for extreme industrial environments. Their explosion-proof luminaires ensure safety, reliability, and performance across oil & gas, chemical, and heavy industries.
With innovative technology, robust design, and global compliance, Raytec lighting is engineered to withstand harsh conditions while delivering optimal illumination and long-term efficiency. Learn more here.
