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Lighting case study
Inspection Pit

Inspection Pit PDF

Overview

Freightliner is an international rail freight haulage company. It moves more than 750,000 maritime containers each year and operates more than 200 locomotives. Freightliner carries out in-house maintenance on its own fleet, and for third parties, using purpose-built facilities.

A leading Mechanical and Electrical consultant asked Kellwood to provide an inspection pit lighting solution, this time for a new Freightliner maintenance site in the south-east of England.

Goals and Challenges

  • To provide a compliant lighting scheme that provides safe transit along inspection pits, while also offering high levels of illuminance to the underside of locomotives and rolling stock.
  • To minimise operating costs – lowering electricity usage and reducing the site’s carbon footprint.
  • Some inspection pits are subject to potentially explosive hazards; lighting hardware must be designed to avoid the accidental ignition of gases.
  • Inspection and maintenance pits are industrial environments, where products can be knocked, and broken.
  • Welding is often undertaken near lights, which can accidentally activate automatic welding masks.
  • The solution should be compliant with emergency lighting requirements.
  • Inspection Pit Gallery Image
  • Inspection Pit Gallery Image 2

Design Process

Kellwood modelled the inspection pits and carried out lighting designs. Multiple calculation surfaces were included to assess vertical illuminance at floor level, and at a typical working height.

Kellwood’s optimised LED solution used low-energy Stephenson Series hazardous area linear lights. They could deliver the necessary lumen package to meet specification targets:


MinimumTargetDesign Achieved
Average Lux>300 lux>500lux530lux
Uniformity>0.4>0.40.43


The Results

Freightliner received a compliant inspection pit lighting solution that helped reduce site running costs, reduce their carbon footprint, while ensuring their staff remained safe and productive.

Product Features

ATEX Certified:
The Zone 1 certified Stephenson Series is suitable for installation in this potentially explosive atmosphere, helping to keep staff safe.

Wire-in-Wire-out:
Lights could accommodate wire-in wire- out installation. This removed the requirement for additional ATEX junction boxes and reduced overall costs

Maintained Emergency:
An integrated 3-hour emergency option was supplied to ensure compliance with escape-route requirements. This simple emergency solution was cheaper to install than a non-maintained emergency lighting option.

Robust housings and Wire Guards:
The impact protection of an already robust fitting was enhanced to IK10 by the inclusion of stainless-steel wire guards. Guards mitigate damage to fittings, avoiding excessive repair costs, and protect the client’s investment.

Robust housings and Wire Guards:
The impact protection of an already robust fitting was enhanced to IK10 by the inclusion of stainless-steel wire guards. Guards mitigate damage to fittings, avoiding excessive repair costs, and protect the client’s investment.

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