THT-EX AC DIRECT LED LIGHTING SOLUTION 1

LED Lighting Service Lifetime, Reliability and Safety

An overview of THT-EX’s dedicated solution for

LED Lighting in hazardous (classified) applications

Top Hi-Tech Co. Ltd

9F, No.1, Zhongshan Road, Tucheng Dist. New Taipei City, 23680, Taiwan.

Internationally certified AC Direct Explosion Proof LED and waterproof LED Lighting solutions from Taiwan!
THT-EX AC DIRECT LED LIGHTING SOLUTION 2

Abstract

At present, manufacturers are designing and developing LED sources using a wide range of materials and

approaches, fueled by the rapid improvement and evolution of multiple core technologies. Lifetime and reliability are often

at odds with cost in the battle to achieve greater market deployment.

Market actors have attempted to reduce user uncertainty about the lifetime and reliability of LED products in various

ways, ranging from unsubstantiated marketing claims, to the use of standardized metrics, to a more recent focus on product

warranties. All present challenges, unsubstantiated claims take time and effort to uncover, and initially may be overlooked

if presented by a known brand.

While warranty coverage is the most important assurance for many users, manufacturer warranty terms vary

significantly—making comparisons difficult if not impossible—and most manufacturers find it impossible to absorb the

financial commitment required to provide warranty coverage on par with the expected (long) lifetime.

Early experiences with some LED products has shown that, while the LED packages themselves may be long-lived

and have acceptable lumen maintenance, driver failure can cause what initially looked like a successful installation to fall

short of client expectations. The time and cost required to address failures can be a function of luminaire construction.

Also almost the entire Solid State Lighting market remains focused on products that fit into the existing

infrastructure of legacy lighting products. This is true for lighting product form factors, customer expectations, and lighting

product functionality. While this is a necessary and expected consequence of introducing a radically new technology into a

mature market, the current market focus sharply limits the potential for the new technology. The sooner the market begins

to transition away from its legacy focus, the sooner SSL can deliver deeper energy savings, and generally better lighting

performance possible only with luminaires designed from the ground up to handle LED light sources.

It is therefore only natural that manufacturers developed LED products to fit into this infrastructure and paradigm.

But to make LED products function well in that infrastructure, product designers have been forced to sacrifice product life,

lumens, controllability, cost, energy efficiency, and lighting quality. Energy is wasted because lumens are wasted, and

because the LEDs have to be driven relatively hard to produce high light output from the limited size. Finally, the product

life is shortened due to high-temperature operation caused by dense packaging of LEDs and electronics within that small

form factor.

Excerpt: US DOE Solid State Lighting R&D Plan 2015

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LED Lighting Service Lifetime, Reliability and Safety

The first question that might needed to be asked particularly to newer technologies is “how will it fail?”

By literally understanding the operation of a certain device or equipment, then we could be able to determine how

to get the most out of its service life and how to make sure that it’s performance could reach the actual users expectations.

All lighting products fail at some point either for Traditional or for the New LED technology; that is, they reach the

end of their useful life. Under normal use and conditions, product failure results from design flaws, manufacturing defects,

wear-out mechanisms or just simply as its expected service-life span. So now the big question is, how to get the most out of

these promising technology?

Introduction

At Present the economic and energy cases are clear but many end users are still in the early stages of

understanding the LED technology especially for the Oil & Gas, Energy and Industrial applications, which leads us to the

following concerns:

o How to distinguish appropriately performing products from others that are not?

o How to address product limitations and factors that causes user dissatisfaction?

o Despite the promise of Long Life, there is no standard way to rate the lifetime of LED products

o Is the LED technology mature enough?

o Is it the right time to start Testing and using LED for lighting?

o Should we already be rethinking and including new LED lighting solutions in future budget planning?

Aside from the fact that change is inevitable to a growing and developing industrial world, but the reality still

remains that adopting new technologies takes time and requires an established understanding of these innovations.

So far, different perspectives are brought about in order to qualify such improvements in terms of Business and

Engineering point of views.

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Business Perspective Engineering Perspective

Upfront Cost (CAPEX) As per requirements
Operational Learning Curve (OPEX) Familiarity
Competitive Landscape Reliability
Widespread Adoption Safety
Compactness
Easy and quick to get

Putting all of these facts into a measurable format of information will lead us to the data as shown below. These

details can provide us an objective way and general view of the “Total Cost of Ownership”.

High Pressure LED THT-EX

Criteria Metal Halide Fluorescent
Sodium with Driver AC LED

Light Source2 Ave. Rated

<20,000 <24,000 <12,000 >50,000 >50,000
Life (hours)
Ballast / Driver Ave.
10,000 10,000 10,000 10,000 >50,0003
Rated Life (hours)
Electrical Power
$$$$ $$$$ $$ $ $
Consumption

Luminaire Upfront Costs $$ $$ $ $$$$ $$$

Lamp (Bulb)
4x 4x 7x 0x 0x
Replacement
Ballast / Driver
9x 9x 9x 9x 0x
Replacement1
Parts Replacement
$$$$ $$$$ $$$$ $$$$ 0
Labor & Equipment Costs
Luminaire / Component
$$ $$ $$ $$ 04
Stocks
Storage Area for
Luminaire / Components $$ $$ $$ $$ 0
Stocks

1. Frequency of replacements are computed based on a conservative maintenance plan, implemented upon within 60% product
life span.
2. Service life of Bulb for Traditional Lighting and LED Chips for Solid State Lighting
3. THT-EX AC Direct LED does not use any Driver components or Ballast, this value is to represent the LED module service
life as a total package, and >50,000 hours is the light intensity degradation to 70% of the original light output, thus the LED
lighting engine can last up to 100,000 hours if with acceptable light output
4. THT-EX products are exclusively manufactured in Taiwan, that is located at the heart of South East Asia, wherein is arms
reach to deliver products right away

Referring to the table above, literally we can assess that the LED surpasses the traditional lighting in every aspect of

the listed criteria. Though in the previous years, LED had gained the impression of being very costly due to the high
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upfront costs, these are compensated by the significant savings and benefits due to the Low Cost Power Consumption

(85% less), “Maintenance-free” and remarkably the long service life that it is popular with, 50,000 ~ 100,000 hours.

Ideally, following the recommended environmental conditions and limitations of the products, and in

accordance to the following user scenarios, we can determine that the LED can last to at least 10 years if use by

8 ~ 12 hours a day.

50,000 hours Scenarios Life Expectancy

powered 4 hours/day 34 years
powered 8 hours/day 17 years
powered 12 hours/day 11.4 years
powered 24 hours/day 6 years

Then of course, every manufacturer defines this within accordance to the product limitations such as to

the recommended Operating Temperatures, Environmental & Mechanical conditions and the prevailing industry

standards.

But what is merely overlooked here is that, this information of 50,000 hours is referring to the LED

Chips, the light source component only, and not to the total luminaire where there are more parts included such

as the Driver components.

Comparison of THT-EX AC Direct LED and other LED lighting with Driver is shown below:
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Common LED Driver consists of Transformers, Capacitors and other Electronic parts. General

knowledge is that, the Capacitor could only have a service life of approximately 10,000hours. Now just like the

LED chips, the driver is affected greatly by heat, that’s why for LED application it is crucial to pay attention to

the Heat Management to get the benefits of this technology.

The cooler the LED is, the brighter and the longer its lifespan, while also exposure of the driver to high

heat, shortens its life expectancy, making a replacement necessary.

THT-EX AC direct LED lighting module does not uses these inefficient components. By utilizing power

electronic devices we are able to remove other components and integrate the electronic devices to the LED. The

luminaire now as a whole can go through an overall endurance and reliability performance tests, it is then

literally operated and verified together as one and not as separate parts.

The simple principle but very effective concept behind this can be expressed by quoting “Less

components means lesser chance of Failure”.

As well having such low profile LED engine module, THT-EX are able to greatly reduce and remove the

bulky size of the enclosure, now this leads to better handling of the Luminaire.

Size comparison of other LED Brands with Drivers and THT-EX AC Direct LED lighting solution:
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Heat Management - Realities of industrial applications

The most popular way of removing heat from any electronic devices is through a heat sink. Finned heat

sinks major function is to increase the surface area where heat can dissipate to the air away from the heat source

through the concept of “Thermal Convection” or “convection heat transfer”

Following the LED heat sink design according to conventional heat management techniques such as the

Thermal Convection, without sufficient air flow or fluids to help cool it down, will result to its early failure.

Especially if it is intended to be used in harsh and hazardous environments such as in Oil and Gas refineries,

Chemical processing plants, Drilling and Exploration rigs, and Heavy Industrial facilities.
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Oil & Gas and Industrial set-up are prone to the following:

• High Humidity and Ambient Temperatures

• Dirt and Dust accumulation

• Foreign material buildup

• Oil residual

• Rust formation & Metal degradation

• Application of corrosion resistant coating

To provide the most suitable solution, we need to understand first the root cause of the problem. Like for

LED lighting, which claims to have long service life, then it is just essential to consider the actual scenarios of

years of installation and the environmental conditions that it will be exposed to.

The product performance is not only about the initial installation or the very beginning of its operation

where it is at its optimum condition, but it is about the effects of its surroundings to its entirety knowing that it

can be installed for many years in such unforgiving environmental conditions. But before it can operate for

many years, will its heat dissipation capability still be effective if it’s covered with dust, dirt and other foreign

materials?
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In addition to that, exposure to even small amounts of Chemical or corrosive elements in the air, High

temperatures and Humidity will lead to corrosion of the metal, the heat sink itself will be degraded eventually.

With this situation, the heat sink would not be able to perform as it should be, resulting to the early failure of the

LED engine due to the heat sink’s inability to transfer the heat into the air effectively.

THT-EX “Thermal Balance” solution

With this understanding and analysis, we could now recommend a more suitable solution. By

matching the amount of heat coming from the LED engine with sufficient amount of material of the heat sink,

we are able to achieve an optimal heat transfer through “Thermal Conduction”.

The heat source is cooled under the thick plate of metal instead of being cooled to direct heat transfer

with flowing air as with the finned heat sink or “convection” process.

Thus even with dust or dirt over the enclosure or with the application of corrosion resistant coating for

further protection to severely corrosive environments, the LED engine is protected and will not over heat which

causes and usually becomes the reason for the product to fail.

By maintaining the heat within the LED engine’s specifications, then we are able to achieve “Thermal

Balance”.

A balance and harmonious relationship between the Heat, Materials and Environment are the building

blocks of proper heat management, it is all about considering the environmental factors during the continuous

operation of the LED engine.

LED/ Heat source

Heat sink/ Thermal conduction

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Failure of Other Components.

Heat levels of LED Luminaires can reach 85°C up to 100°C or more for high powered LED lighting. In

the event of heat being released into the air by applying the Finned heat sink design, heat radiates upward where

the driver is normally located. This is aside from the direct heat transferred from the Heat sink side into the Driver

enclosure.

With this significant heat transferred into the Driver, the components lifespan are greatly affected and

causes premature failure.

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THT-EX LED Benefits and Advantages

After knowing the actual considerations on how to really ensure the promised service life of the LED,

we can now realized all the benefits and advantages that this technology could bring to our generation and the

next. As we can be assured that this technology can serve its purpose thru its long life, finally we can now

achieve the improvement that this innovation will bring to many applications.

Low Power Consumption

Compared to traditional lighting, LED in general consumes much less electrical energy with light

outputs to match or even brighter than the existing source of lighting. Where also the disadvantage of the

traditional lighting, especially HPS, is that at its half-life, its intensity is reduced to 50%, meaning that the

power consumption is the same but with half of the output light for its remaining service life.

While the benefits of LED is widely known to us, in reality, not all LED lighting products are created

and manufactured equal. It depends on the desired purpose and functionality according to the application it is

intended to be used.

For THT-EX we are able to recommend equivalent lighting intensities based on our own performance

test according to its intended used to the Heavy Industries, Oil & Gas, Harsh and Hazardous (classified)

locations.

The recommended Lighting Power equivalent is shown in the table below, but the final implementation

will still depends on the end users preference.

THT-EX
HID Power Remarks
Equivalent (W)
100W for height below 6meters
400W 100W or 120W 120W for height over 6meters
80W for height below 3meters
80W, 100W or
250W 100W for height below 6meters
120W 120W for height over 6meters
60W for height below 5meters
150W 60W or 80W 80W for height over 5meters
60W for height below 5meters
175W 60W or 80W 80W for height over 5meters
40W for height below 3meters
100W 40W or 60W 60W for height over 3meters
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Maintenance-Free

How do we define “Maintenance-Free”?

If we keep on repairing, replacing parts or components, then it is not maintenance-free at all.

Generally, conservative maintenance is implemented when products reaches 60% of its lifespan,

o this is true especially when replacing Lamp Bulbs of HID lighting and Ballast or its components.

o while general LED lighting design, do not have bulbs to be replaced but uses Drivers that

consists of Transformers, Capacitors and other components failing much earlier than the LED

itself and of course it is needed to be replaced.

THT-EX AC Direct LED lighting solution does not have both lamp bulbs and drivers, as well it is

protected to corrosion, it is waterproof, and even with dust and dirt over its body, will never be a concern due to

its “Thermal Balance” design dedicated to withstand the various harsh environmental conditions.

Now, virtually we can say that THT-EX have a really “Maintenance-Free” LED lighting solution.

LED with THT-EX AC

Criteria HID
Driver Direct LED
Lamp Bulbs Replacement YES NO NO
Starter / Igniter Replacements YES NO NO
Driver/ Components Replacements YES YES NO
LED & Driver Wiring and terminations YES YES NO
Affected by High Temperature 100°C, operating
YES YES NO
continuously for 100hours
Affected by Humidity / Steam @100°C, operating
YES YES NO
continuously for 200hours
Heat Sink affected by Dust /Dirt / Oil covering
YES YES NO
Rust, Corrosion resistant coating
Vibration resistant NO YES YES

2 million times On/Off switching operation UNKNOWN UNKNOWN YES

60 m/s Wind Force endurance (Typhoon category) UNKNOWN UNKNOWN YES

Frozen Water / ICE immersion and instant on test UNKNOWN UNKNOWN YES
THT-EX AC DIRECT LED LIGHTING SOLUTION 13

LED with THT-EX AC

Criteria HID
Driver Direct LED
-70°C Freezing point and instant on test UNKNOWN UNKNOWN YES

Corrosion simulation testing UNKNOWN UNKNOWN 1,000 hours

Impact durability (Glass) UNKNOWN UNKNOWN 4 joules

Waterproof & Dustproof IP65 / IP66 IP65 / IP66 IP67 / IP68

Warranty

THT-EX offers 5 years warranty, based on the fact that there’s no components or parts to be replaced or

maintained, thus in case of lamp failure, it will be replaced as a whole.

While operating the LED luminaire for 24 hours a day will bring it to about 6years of service lifetime

where it will reach its 70% light intensity degradation, and if there’s enough or acceptable lumen output, then

this can extend its use to 100,000 hours lifespan.

50,000 hours Scenarios Life Expectancy

powered 8 hours/day 17 years
powered 12 hours/day 11.4 years
powered 24 hours/day 6 years

Safety

Safety is relied not only thru specification sheets, but by actual performance of the product. There’s

nothing more valuable than the security of life in these critical applications, thus every bit of information is very

crucial and cannot just be proved by any document alone.

THT-EX have been performing product evaluations not only within the limitations of the International

and Industry standards, but beyond what are set by the authorities. Pushing the limits and boundaries of the

product capability can prove THT-EX’s broad experience in undertaking varying environmental conditions.
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Considering there are many factors beyond the specifications set in the standards affecting the

performance of the product. This can possibly break it or downgrade the luminaire’s actual output and can cause

disastrous events to the facility.

From Onshore to Offshore, Cold & Hot temperatures, Humid and Wet surroundings, to Marine and

severe environmental situations, THT-EX have gain numerous experiences from different applications

worldwide. This only justifies our capability in conquering demanding applications that we are able to impart

into the development of the LED lighting solution.

With less maintenance, less handling and trusted reliability of the THT-EX AC LED lighting, it reduces

the chances of people going into critical maintenance routine checks that simply exposes personnel to dangerous

tasks.

Reduction of maintenance / replacement of failing components, mistakes and human error upon opening

and closing the enclosure for maintenance or even able to simply adjust maintenance schedules to annual checks

will definitely lessen potentially hazardous activities involving the personnel and the overall safety of the

facility.

High Pressure LED THT-EX

Criteria Metal Halide Fluorescent
Sodium with Driver AC LED

Light Source Ave. Rated

<20,000 <24,000 <12,000 >50,000 >50,000
Life (hours)

Ballast / Driver Ave.

10,000 10,000 10,000 10,000 >50,000
Rated Life (hours)

Lamp (Bulb)
4x 4x 7x 0x 0x
Replacement
Ballast / Driver
9x 9x 9x 9x 0x
Replacement
Note: Table information is based on Ideal conditions and standards
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Customization

THT-EX can provide design solutions, retrofit replacements, various mounting configurations and total

customization as per the customer’s request. The R&D department are equipped with engineering experience and

technical know-how that can serve any requirements by the customer.

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Lighting Simulations

THT-EX can support lighting simulations as needed, this involves working collaboration with the end

user’s engineers to be able to provide the most efficient and suitable recommendations as per requirement.
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Site Visitation

THT-EX are reaching out from Taiwan, to North America, South East Asia, and even to Middle East. As

we know that Oil & Gas explorations, Refineries, Petrochemical Plants, Power Generation companies, Coal

Sheds, Paper Mills, Gas Distribution Systems, Tanks and Storage, Industrial Facilities, Offshore platforms and

other related sites are remotely located to far distant locations. We in THT-EX are able to extend our support by

visiting your site for actual assessment and discussion.

In this way we are able to understand the actual details needed to ensure the correct service will be

offered to you. We are confident to face, to represent and discuss to our customers the details they need to

understand about the LED technology and help them decide by having the correct understanding of the LED.

Technology, Product Presentation and Discussion

Along with site visitations, we encourage the discussion with technical engineers and related personnel

involve in finding the right LED lighting solution for their system. For this we provide a technology and product

presentation where we can discuss in detail the AC Direct LED lighting solution for Harsh and Hazardous

(classified) location.

We can set appointments and meeting schedules accordingly just let us know when and where.
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Global Certifications

In accordance to the industry standards and certifications, we have gathered the major approvals listed

below in no particular order.

Marking Description Country

IECEx -
International Electrotechnical Commission Explosive
INTERNATIONAL

UL - Underwriters Laboratories NORTH AMERICA

ATEX - ATmosphere EXplosibles EUROPE

CML - Certification Management Limited

TIIS - Technology Institution of Industrial Safety
JAPAN

NOM - Norma Oficial Mexicana MEXICO

KOSHA - Korea Occupational Safety and Health Agency KOREA

TS mark by Industrial Technology Research Institute

(ITRI)
TAIWAN

GB – Guobiao
(Chinese for national standard)
CHINA

ABS - American Bureau of Shiping

CR Classification Society

ISO 9001 and ISO 14001

QAR – Quality Assessment Report

QAN – Quality Assurance Notification
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Conclusion

All in all, we can say that THT-EX only offers our customers the understanding that they need to have

about the LED technology.

“Because it doesn’t matter how many resources you have, if you don’t know how to use them, it will

never be enough”

Thus it is just fair to provide anyone who thinks that LED will be the suitable lighting solution for their

application the know-how and knowledge behind the total LED lighting solution in order to move forward and

achieve the benefits of this innovative lighting technology.

In Summary, this is what THT-EX is offering:

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THT-EX

www.tht-ex.com

This proposal was prepared specifically for your reference only. The information presented
herein makes no warranty to correctness and achievement. Reproduction and/or distribution of the
information presented herein by any means without express permission of TOP HI-TECH CO., LTD are
strictly prohibited. All information herein without limitation to the methodology, terminology and models
are proprietary with copyright of TOP HI-TECH CO., LTD .