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 The brief was clear: replace an outdated and inefficient 400W SON system with a modern LED solution to improve safety, reduce energy costs, and meet winter-readiness timelines.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:
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.
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 for your next lighting upgrade. We provide technical expertise, site surveys, and reliable supply of Raytec hazardous area lighting.
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.
A turnkey hazardous area heating solution for safe chemical storage – from concept to completion
Thorne & Derrick delivered a fully bespoke ATEX certified heated storage container to a multinational biotechnology company, enhancing safe, compliant, and energy-efficient heated chemical storage in a hazardous environment. This complex and fully compliant solution replaced an outdated boiler system.
Through proactive outreach, Thorne & Derrick engaged with the client, leading to a site visit to assess the situation. Recognising the client’s need for a modern electrical solution, Thorne & Derrick spearheaded the design and delivery of a fully bespoke heated storage container. Thorne & Derrick worked together with several supply chain partners to design and deliver a temperature controlled storage unit including the use of latest fan heater technology from EXHEAT.
The client required a container with a capacity of 48 barrels or 12 IBCs. The challenge was to provide a controlled heating solution that could heat up and maintain ambient temperatures as per the chemical manufacturers guidelines.
A full Factory Acceptance Test (FAT) was conducted, with the client’s engineers attending site to inspect and sign off the solution prior to delivery. This ensured full satisfaction with the build quality, safety features, and operational readiness.
A critical component of the build, the EXHEAT LFH was selected as the only ATEX-certified fan heater on the market approved for use with rigid front and rear ducting. This unique design was essential in satisfying the client’s strict safety requirements for hazardous area operation. The LFH enabled safe, controlled warm air distribution within the container, while its robust, compact design and proven reliability made it the optimal choice for this application.
The heater has a built in safety features including an automatic over-temperature cut out. Additionally ambient temperature control for low and high temperature alarms was built into the control system. Further the system was designed for the fan to run constantly and ensure even air circulation and thermal consistency. To maximise space internally the heater was fitted to the rear of the container which also provided easy access for maintenance.
Close up of LFH Fan Heater by EXHEAT
LFH Fan Heater Fitted to Back of Bespoke Heated Cabinet
Bespoke Heated Cabinet – LFH Fan Heater
Aerial View of LFH Fan Heater
Aerial View of LFH Fan Heater
Alternative View of EXHEAT LFH Heater
Fully custom-built solution designed for hazardous area chemical storage. Features include ATEX-certified fan heater with rigid ducting, custom control panel, and optimised internal layout to store up to 48 barrels or 12 IBCs safely and efficiently.
| Client | Multinational Biotech Firm |
| Sector | Pharmaceutical |
| Solution | Bespoke ATEX Certified heated storage container |
| Heating System | EXHEAT LFH fan heater |
| Capacity | Up to 48 barrels or 12 IBCs |
| Timeline | ~12–16 weeks |
From Concept to Completion
What began as a conversation and a client idea was brought to life through engineering collaboration, application expertise, and a robust supply chain.
Conclusion
This project exemplifies Thorne & Derrick’s capabilities as solution sellers—taking a complex challenge from idea to installation, delivering compliance, safety, and operational excellence in hazardous area environments. From initial consultation to final commissioning, Thorne & Derrick is your trusted partner in EX-rated heating innovation.
Get in touch with our experts to learn how we can help. Whether you need to safely heat chemicals, prevent product freezing, or maintain critical temperatures in a hazardous area, Thorne & Derrick can deliver a fully compliant, end-to-end solution tailored to your operational needs.
Project: Sample Analytics Form (Process Emission Control)
Location: Dubai, UAE
Scope of Supply:
Engineering & Design (EP)
Procurement of Sample Analytic Lines for Emission Control and Monitoring
Supply of Heated Hoses with Series Heating Cable
Integrated temperature sensors for precise monitoring (up to 160°C)
Hazardous area-rated components with Ex-Control Systems
Power distribution boxes for controlled and reliable system operation
Application:
The heated sample line system was designed for critical emission control and monitoring applications in a hazardous environment. The solution ensured sample integrity through heated transfer lines, preventing condensation and enabling accurate gas analysis.
Technical Highlights:
Heated hoses designed for 160°C operating range
Ex-rated instrumentation for hazardous zones
Integrated temperature control and safety systems
Power distribution tailored for site-specific requirements
Year of Supply: 2019
Outcome:
The heated sample lines provided Petroleum Development Oman with a robust, safe, and compliant solution for emission control analytics, supporting environmental monitoring efforts in line with regional regulations and internal ESG goals.
With more than four decades of industry expertise, Thorne & Derrick are recognised leaders in delivering specialist trace heating solutions for a wide range of industrial applications. From hazardous zones and extreme climates to critical process control systems, we design bespoke solutions tailored to the specific needs of your operation.
Our services include comprehensive in-house heat loss analysis, system design, and technical specification, backed by a commitment to engineering excellence. Using only premium, market-leading heat trace cables and components, we provide cost-effective systems that enhance operational efficiency, minimise downtime, and support long-term project reliability—from initial concept through to full commissioning.
The Tangguh LNG Expansion Project in Papua, Indonesia, is a significant development aimed at increasing LNG production capacity. The CSTS consortium—comprising Chiyoda, Saipem, Tripatra, and SAE—was awarded the EPC contract for this large-scale project.
Project: Tangguh LNG Expansion Project
Natural Gas Distribution
Location: Papua, Indonesia
Eltherm was selected to deliver a comprehensive Electrical Heat Tracing (EHT) package. The scope included:
Engineering, Design & Material Supply
Electrical Process Heating Systems (EPS)
Monitoring & Control Systems
Supervision & Training
Total Heating Cable Supplied:
20 km of ELSR (Self-Regulating Heating Cables)
10 km of MI (Mineral Insulated Heating Cables)
520 m of ELK (Series Resistance Heating Cable)
Total Heating Circuits: 602
Panels Supplied: Distribution Panels with integrated monitoring & control
The EHT solution provided ensured reliable freeze protection and process temperature maintenance across the facility. By deploying a combination of self-regulating and mineral-insulated heating technologies, the system achieved high efficiency, safety, and long-term performance in challenging environmental conditions.
With more than four decades of industry expertise, Thorne & Derrick are recognised leaders in delivering specialist trace heating solutions for a wide range of industrial applications. From hazardous zones and extreme climates to critical process control systems, we design bespoke solutions tailored to the specific needs of your operation.
Our services include comprehensive in-house heat loss analysis, system design, and technical specification, backed by a commitment to engineering excellence. Using only premium, market-leading heat trace cables and components, we provide cost-effective systems that enhance operational efficiency, minimise downtime, and support long-term project reliability—from initial concept through to full commissioning.
Project: Rehabilitation of Fuel Gas Lines – Offshore Heating Solution
Application: Process Temperature Maintenance for Offshore Gas Pipelines
Location: Cairo, Egypt
Engineering, Procurement, and Design (EPD) of 1 km of high-temperature Self-Regulating Heating Cables (ELSR-H), designed for use in hazardous areas.
Local Ex-approved temperature controllers to maintain consistent process temperatures for fuel gas lines on offshore platform facilities.
Collaboration with a local contractor for on-site installation and commissioning.
This project supports the safe and efficient transport of fuel gas by ensuring reliable pipe temperature maintenance, even in extreme offshore environments using high-temperature heat trace. The solution provided aligns with the client’s operational safety requirements and energy efficiency targets.
With more than four decades of industry expertise, Thorne & Derrick are recognised leaders in delivering specialist trace heating solutions for a wide range of industrial applications. From hazardous zones and extreme climates to critical process control systems, we design bespoke solutions tailored to the specific needs of your operation.
Our services include comprehensive in-house heat loss analysis, system design, and technical specification, backed by a commitment to engineering excellence. Using only premium, market-leading heat trace cables and components, we provide cost-effective systems that enhance operational efficiency, minimise downtime, and support long-term project reliability—from initial concept through to full commissioning.
Published 13 Mar 2020
Press Release Date: 02.04.2020 uploaded by Chris Dodds (T&D Sales + Marketing Manager) World’s First Fully Certified ATEX Doors Thorne & Derrick International, the Experts in Equipment for Explosive Atmospheres, today announce the signing of a Commercial Distribution Agreement...
Published 04 Jul 2019
Press Release Date: 04.07.2019 uploaded by Chris Dodds (T&D Sales + Marketing Manager) Category: Stockist Distributor Agreement Announcement Thorne & Derrick International announce that they have signed a Preferred Distributor Agreement with Raytec, the world leading manufacturer of LED...
