Industrial lighting renovation

Transcription

1 Indus trial lighting renov Industrial lighting renovation BEST PRACTICES

2 Conventional Superior Performance Superior lighting pays for itself... With rising energy costs and a volatile energy future, businesses are finding that they can better meet their financial goals through energy conservation measures, which can immediately and substantially impact bottom line performance. In most businesses, energy required to operate lighting equipment is a large percentage of the overall energy bill, therefore new and energy-efficient lighting equipment is often a solid investment. Renovating the lighting system in an industrial space can result in substantial energy savings even using conservative numbers, payback can be realized in as early as 6 months. Using the latest in optical, electronic and thermal management technologies, Acuity Brands Lighting provides a wide array of luminaires and other lighting equipment, to address the many varied needs of industrial spaces. Acuity Brands Lighting possesses the capability for providing quality lighting at the lowest total cost of ownership. Under such leading brands as Lithonia and Holophane, Acuity Brands Lighting is committed to providing the best lighting solution, that not only saves energy but also enhances safety and productivity in the work space. An example of Better lighting at lower cost: Multinational Company XYZ operates a large manufacturing facility. The plant s energy-inefficient HID high bay fixtures were decades old; the aluminum reflectors had gathered dirt and grease from welding fumes and other production processes, and the horizontal illuminance light levels were only 160 lux. Compounded by the yellow light from high pressure sodium lamps, the space felt gloomy, visibility was poor and all objects looked brown. The local Acuity Brands Lighting representative was called in to survey the existing situation and to propose a renovation plan that would both improve the quality of light and slash energy consumption. Holophane s RE high bay fixture with pulse start ballast and lamp system was selected, and a 6 fixture mock-up was installed over one production cell. Employees were thrilled by the white light and brightly lit space, and the plant s management decided to implement Acuity s renovation proposal. When the renovation was complete, horizontal illuminance level had been raised to 550 lux average, finally meeting the lighting specifications required for Company XYZ to uphold its manufacturing quality standards. The new lighting cuts energy cost by 1/3 and maintenance cost by 50%. Employees are happier, productivity has been improved, and errors and rework have been reduced. The plant management is advising its suppliers to follow suit, renovating their plants with the environmentally-friendly, energy saving, quality-enhancing Acuity Brands Lighting solution Superior lighting 02 03

3 ENVIRONMENTAL CONSIDERATIONS The Lighting Renovation ProcesS 1 2 By following a best practice workflow process, you can be assured of a lighting solution that improves lighting performance, saves energy and delivers quick economic payback: Specification determine criteria on lighting, lighting equipment and energy savings, adopt or modify existing specification, use local lighting standards as reference. Lighting audit perform jobsite lighting level measurements, inspect conditions of existing lighting equipment, obtain/ confirm space parameters and ambient conditions. Does existing lighting system provide lighting that meets design specification and local standards? Are the luminaires equipped with up-to-date energy saving ballast and lamp technologies? The lighting practitioner must take into account a variety of environmental factors: The space - ceiling height, work plane height, room surface finishes, fenestrations, existing wiring and equipment locations The ambient dust and dirt, moisture, airborne grease, potential presence of flammable gaseous chemicals, temperature, vibration and incidental abuse Visual tasks sizes, color, texture, contrast of objects, viewing angles of observer, glare Flexibility and control requirements a facility s need to relocate equipment and change task locations within the space; reduction of illuminance in non-productive hours or to take advantage of daylight harvesting ENVI RON MEN TAL Lighting analysis choose renovation lighting products, perform layout and calculation of illuminance and uniformity using lighting application software such as Visual, compare results with lighting audit data taking into account light loss factors. Economic evaluation perform financial analysis, compare total cost of ownership between existing and renovation systems, determine payback. Mock-up Install new fixtures in a small area and see the difference firsthand. Visit similar projects Visit lighting installations utilizing the same or comparable lighting solutions. Experience quality lighting in action; validate. Safety minimize on-the-job-injuries: proper color rendering of safety color signage, accurate modeling of objects, reduction of glare, and providing a clear path of egress during an emergency, even through smoke Maintenance durability of lighting equipment and long lamp and ballast life allows for longer periods of time between cleaning and relamping Ease of access for service and replacement Energy requirement local energy conservation measures may require meeting maximum watts-per-square-foot criteria Regulatory compliance local electrical safety standards on lighting, electrical equipment, and installation methods questions to consider As with any significant financial investment, evaluate your potential lighting suppliers and ask questions: Are their products certified to accepted safety standards such as UL? Do they provide photometric data for their luminaires? Are the data obtained from actual measurements? Are their representatives knowledgeable about all facets of lighting and the specific application for your project? Are the representatives touting their products only for low prices, or are they interested in providing a quality lighting solution with the lowest total cost of ownership (long-term solution)? 04 05

4 visual software Developed by Acuity Brands Lighting, Visual is a collection of lighting calculation tools and powerful 3D modeling software engineered to simplify the design process and provide a comprehensive analysis for advanced lighting projects. Visit to download a free trial of the latest version. illumination considerations A quality lighting renovation is designed to meet a certain set of performance criteria. Lighting performance can be predicted through calculations using lighting application software and by taking into account factors that bear upon the quantity and quality of the light: Illuminance primary measure of the amount of light on work planes (horizontal and vertical), expressed in units of lux (SI). Illuminating engineering societies or other regulatory agencies recommend illuminance levels for different types of activities and visual tasks. Many visual tasks such as instrument gauges and stocking shelves are located on vertical planes, therefore vertical illuminance levels are an important factor in choosing lighting fixture photometric distributions. Obstructions must be taken into account. llumination Uniformity essential for good visibility and minimizing visual fatigue in most general industrial applications, but not required in instances where a higher level of contrast is needed to accurately render objects or perform detail-intensive tasks Color rendering the ability of a light source to represent the true colors of an object, measured by color rendering index (CRI). Metal halide and fluorescent lamps are preferable to high pressure sodium lamps. Contrast task contrast must be made as high as possible to ensure an object s visibility against the background Shadows soft shadows enhance depth and form of objects while harsh shadows reduces visibility and cause visual fatigue Glare both direct glare (resulting from light traveling directly from lamp to the eye) and reflected glare (resulting from lighting reflected from glossy surfaces) can cause fatigue, discomfort, and reduced visibility resulting in a loss of productivity, and a possible safety issue. Light Loss Factors (LLFs) LLFs are used to adjust lighting calculations from a controlled laboratory environment to actual field conditions, or from an initial installation condition to the same installation s maintained condition, over a predetermined time frame. Total LLF includes several factors that affect the practical, usable light. The following LLFs must be taken into consideration when designing an effective lighting solution: 1. luminaire Dirt Depreciation (LDD ) which accounts for light loss due to accumulation of dirt on luminaires 2. lamp Lumen Depreciation (LLD) the lowering of light output of lamps over their operating lives. 3. thermal Factor (TF) Fluorescent light sources are sensitive to temperature extremes, and temperatures outside of a fixtures rated optimal range can reduce light output. 4. Ballast Factor (BF) A ballast factor of 1.0 represents a lamp that is operating at full wattage. BF less than 1.0 indicates a lamp will not receive the intended wattage, resulting in lower light output. LIGHT LOSS FACTORS (LLF) LLF (percentage of initial lumen output) X X Years of use without cleaning* X Probe-start, Aluminum/Acrylic Reflector (clean) environment Probe-start, Aluminum/Acrylic Reflector (Dirty) environment Pulse-start, Glass Reflector (Clean) environment Pulse-start, Glass Reflector (Dirty) environment *Based on 10 hours per day lamp burning cycle and typical metal halide depreciation curve X X 06 07

5 con mics economic viewer software Acuity Brands Lighting s Economic Viewer software allows the user to perform easily understood financial comparisons between several lighting alternatives. Whether investigating the economics of a renovation project or deciding between various options in a new construction project, the Economic Viewer considers both initial and annual costs to determine payback periods and rate of return on a lighting system investment. Comparing up to five lighting systems simultaneously, the Economic Viewer will also provide graphical comparisons of accumulated costs over the life of the system in present day dollars. Likewise, it will perform variance analysis, allowing the user to see what changes in variables such as the cost of electricity have on other parameters such as payback period. INITIAL COSTS Cost of Luminaires: Installation of Luminaires: Wiring of Luminaires: Cost of Lamps: Compensating A/C: Savings in Heating Equipment: Total Installation Costs: Initial Taxes: TOTAL INITIAL COSTS: Relative Initial Cost: AVERAGE(*) ANNUAL COSTS Lighting Energy Costs: KW Load of the lighting: A/C Energy: A/C Maintenance: Reduction in Heating Fuel: Reduced Heating Maintenance: Replacement Lamps + Labor: Relamping Ballast + Labor: Cleaning Costs: Insurance + Property Tax: Reduced Income Tax Liability: Other Annual Costs: TOTAL ANNUAL COSTS: Relative Annual Cost: ANALYSIS Simple Payback (years): Discounted Payback (years): Internal Rate of Rate (%): EXISTING SYSTEM 0.00 $ $6, Base Case Base Case Base Case $ $ $6, $ $ LOCAL COMPETITOR $ $ $8, $ $4, (*)=All annual costs have been averaged over the life of the system. Renovated system will eliminate roughly 40 tons of CO 2, 84 kg of NOx, and 173 kg of SO 2 per year In the case of Multinational Company XYZ, improved light levels were reached with 161 Holophane glass luminaires with narrow and wide distributions, replacing 438 HPS aluminum fixtures. Over 2 times the light level, achieved with nearly 1/3 the number of fixtures. Lighting economics Initial cost or unit costs should not be the only consideration when examining the economics of a lighting system. A better gauge is how effectively the entire lighting system will operate over time. State-of-the-art optical systems promote energy efficiency and allow wider spacing between luminaires. Quality materials and a highly engineered design assure the luminaires provide reliable performance with minimal maintenance for many years. Accumlated Total Costs(*) By Year In Today s Dollars $ $ $ $ $ $ $ $ $ $5000. TOTAL COST OF LIGHT Product Cost Installation Cost Energy & Maintenance Costs, 5 Years Existing System No Cost No Cost $34.627,50 Local Competitor $4.446,00 $5.104,00 $3.860,00 $1.980,00 $20.047,50 $11.846, Year Number (*) = All annual costs represent an average over the system life

6 HID Energy Saving Lighting Technologies ID Prismatic glass for optical control For applications where heat, industrial fumes, dirt and moisture are prevalent, an HID fixture with a glass reflector is the best choice. Holophane s borosilicate glass reflectors are designed to meet the most demanding requirements for thermal shock resistance and mechanical strength. Glass does not take on electrostatic charges that attract dirt and dust particles and is resistant to most chemicals and UV degradation. With the heat generated by the lamp, a constant flow of hot air through an open reflector creates a venturi effect that minimizes dirt buildup on the reflector. Additionally, glass can be cleaned and brought back to 100% efficiency. Holophane s prismatic refractor/reflector design delivers precise optical control and maximum efficiency, with distribution patterns that allow the same illuminance and uniformity levels to be met with a smaller quantity of fixtures than those with other types of reflectors. Self Cleaning Airstream Ballast Type Probe start Pulse start Pulse start Lamp wattage Ballast inpaut watts Initial Lumens 36,000 31,000 41,000 Mean Lumens 25,000 26,400 32,800 Mean Lumens per watt Pulse start metal halide ballast/lamp systems While traditional metal halide lamp and probe-start ballast utilize an internal electrode to start the discharge arc, a pulse start lamp does not have the internal electrode and is started by high voltage pulses from an igniter. Available with both Lithonia and Holophane fixtures, pulse start systems present significant advantages over probe start systems: higher initial lumen output faster warm-up and faster hot-re-strike time (4 min.) improved lumen maintenance colder starting temperature (-40 C/-40 F) increased lamp efficacy (lumens per watt) longer lamp lifetime reduced color shift Benefits of one-for-one replacement based on mean lumens (reference) 20% energy savings at comparable light levels 31% more light at same energy cost Number of fixtures to achieve approximately same light levels Holophane s Enduratron TM, with full continuous dimming electronic HID ballast technology, offers unparalleled light quality, distribution, control, and energy savings. Adjustability of HID high bay photometric distribution Different photometric distributions are achieved by adjusting the relative position between lamp and reflector. In Lithonia HID high bay fixtures, the mounting bracket can be adjusted up or down in 11 positions relative to the lamp. Each of the 11 reflector positions represents a different photometric distribution: the lowest position delivers the greatest downward punch while the highest produces the widest spread. The adjustability of photometric distribution enables lighting fixture layout to be fined-tuned according to illuminance requirements and mounting heights so as to achieve the widest possible fixture spacing without compromising lighting performance. Luminaire Dirt Depreciation Accumulation of dirt on luminaires results in a loss of light output. The amount of dirt depreciation or light loss is dependent upon luminaire construction and materials and on surrounding atmospheric conditions. Holophane always utilizes glass reflectors. Glass, unlike acrylic or aluminum, is an inert material that resists the electrostatic charges that attract dirt and dust particles

7 T5HO FLUORESENT HIGH-BAY ENERGY SAVING Lighting Technologies annual operating cost BASED ON: 365 DAYS I 16 HOURS PER DAY I $0.08 COST PER kwh $250 $ $ $200 $150 $ $100 $50 $0 400W Metal halide (6) F96T12HO/ES (4) F54T5HO LAMP TYPE Acuity Brands Lighting offers fluorescent high bay fixtures optimized around the new T5HO lamp and ballast system. Lithonia Lighting s I-BEAM features patent-pending T5HO Cool Running Technology, enabling it to be the first T5HO fluorescent high bay that is UL listed to operate at ambient temperature up to 65 C. - i-beam represents significant advances over traditional T8 fluorescent fixtures: - Higher lamp efficacy (lumens per watt) - Higher initial and maintained lumen output per lamp - higher lumen output in a more compact lamp permits higher lumen package per fixture, thereby requiring fewer fixtures to achieve comparable illuminance levels - Compact lamp and segmented specular reflector combined to deliver greater punch downward, as well as to vertical surfaces, making it possible for one-for-one replacement of 400W HID fixtures. - Cool Running technology overcomes fluorescent s limitations in high ambient temperature environments. - Mounting height is up to 13 meters A 4 lamp (54W T5HO) I-BEAM directly replaces a 400W probe-start metal halide high bay: - 50% energy saving, payback on energy alone is typically less than 2 years - Maintains designed illumination levels over time, with greater uniformity - longer lamp life reduces frequency of lamp replacement - t5ho amalgam lamps operate at peak efficiency from -5 C to 65 C. - instant-on and instant re-strike, versus HID s re-strike time and required alternative power supply. - optional occupancy sensor and ability for daylight harvesting further reduce energy costs - Multiple lamps allow fixture to continue operating even if one or two lamps burn out. - improved color rendering, and more choices of lamp color temperature. Easier to install lamps. - low profile reduces chance of damage by passing forklifts or other vehicles - electronic ballast is quieter than magnetic HID ballast. - a green choice: less steel, less mercury, less freight, 100% recycled corrugated packaging. 1.4 mg mercury per T5HO lamp vs. 67 mg per metal halide lamp. Replacing a metal halide high bay with a 4-lamp I-BEAM reduces mercury content by 92%. t5ho vs. HID fluorescent 12 While there are certain heavy industrial applications where HID solutions are more appropriate, there are certain industrial environments where linear fluorescent lighting is the superior choice. 13

8 ID & 5HO 14 Specific Industrial Applications: Warehouses Packaging areas Textile mills Distribution centers Steel mills Foundries Paper mills Assembly areas Power plants Food processing Chemical plants Wastewater treatment facilities Hangars Inspection areas Breweries Specific Industrial Applications: Warehouses Packaging a Specific Industrial Applications: Warehouses Packaging areas Textile mills Distribution centers Steel mills Foundries Paper mills Assembly areas Power plants Food processing Chemical plants Wastewater treatment facilities Hangars Inspection areas Breweries Specific Industrial Applications: Warehouses Packaging a Specific Industrial Applications: Warehouses Packaging areas Textile mills Distribution centers Steel mills Foundries Paper mills Assembly areas Power plants Food processing Chemical plants Wastewater treatment facilities Hangars Inspection areas Breweries Specific Industrial Applications: Warehouses Packaging a Specific Industrial Applications: Warehouses Packaging areas Textile mills Distribution centers Steel mills Foundries Paper mills Assembly areas Power plants Food processing Chemical plants Wastewater treatment facilities 40m 30m 20m 10m 3m hid & t5ho fluorescent luminaires Covering the Full Spectrum of Industrial Applications Though diverse in environmental conditions, industrial spaces are well served by the combination of HID and T5HO fluorescent luminaires. For general industrial applications, the choice between HID and T5HO fluorescent luminaires is determined mainly by dirt level, ambient temperature and mounting height. The following chart illustrates luminaire type selection, based on these various environmental conditions. Consult your local Acuity Brands Lighting representative for additional information on lamp and fixture options, illumination calculation, fixture layout and economic analysis. Prismpack V: Up to 55 C (optional 65 C), about 40 m DIRTY ENVIRONMENT Prismalume: Up to 55 C (optional 65 C), about 40 m RE Luminaire: Up to 55 C, about 40 m Enduralume: Up to 55 C, about 10 m IBEAM T5HO: First up to 55 C (optional 65 C), about 13 m MS5HB: Up to 35 C, about 10 m CLEAN ENVIRONMENT 15

9 HID & T5H0 fluorescent products other products HID fluoresent T5HO fluoresent other products Synergy, RELOC, EMERGENCY. OFFICE other products Synergy, RELOC, EMERGENCY. OFFICE Holophane - Prismalume - 150W to 1000W, pulse start options - Patented ISD SuperGlass optics - UL listed 55 C standard; 65 C / damp location optional - excellent vertical illumination, suitable for most HID applications Holophane - Prismpack V - 150W to 1000W, pulse start options - Patented ISD SuperGlass optics - UL listed 55 C standard; 65 C / damp location optional - Perfect for heavy duty environments & when emphasis is on down light. Holophane - RE Luminaire - 250W to 400W, pulse start options - Encapsulated ballast, quiet operation - Patented ISD SuperGlass optics - Uncovered & covered glass reflectors - UL listed 55 C, damp location - ideal for light industrial & warehouse applications. Lithonia Lighting - TH High Bay - 175W to 1000W, pulse start options - Aluminum reflector - Adjustable mounting bracket Holophane - Enduralume - 175W to 400W pulse start metal halide; 400W with Elite Series e-hid ballast - thermal shock resistant prismatic glass or acrylic lens - for applications requiring enclosed fixture with wide spread distribution C starting temperature - UL listed 55 C, damp location, optional UL listed 40 C, wet location Lithonia Lighting - I-BEAM Series - 4 or 6 54W T5HO lamps - t5ho Cool Running Technology, 5 yr warranty at 55 C and 3 yr warranty at 65 C - 95% reflective Miro 4 reflector - Ballast access from below, easy for service - options include motion sensor and Reloc flexible wiring. Whic can be used with Synergy Lighting Controls (Check with your local sales representative for voltage offerings) - Suitable for most manufacturing and warehouse applications Lithonia Lighting - MS5HB Series - 2, 3, 4 or 6 54W T5HO lamps - 2 or 3 lamp cross sections, 4 or 6 lamp options available in 8 length tandem units - 95% reflective Miro 4 reflector - optional straight blade louver shields lamps and reduces glare. - options include Reloc flexible wiring and integration with Synergy Lighting Controls (Check with your local sales representative for voltage offerings) - Suitable for aisles and open spaces in warehouse and light industrial applications Lithonia Lighting - RT5 Volumetric Lighting 2 x2, 2 x4 and 1 x4 ; 14W T5, 28W T5 and 54W T5HO Up to 33% energy saving over standard, parabolic-louvered fixture Eliminates glare and dark spots, creates feeling of spaciousness Lithonia Lighting Quantum Series Ideal for applications requiring attractive, quick installation exit signs and low energy consumption Lithonia Lighting Quantum Series Provides a minimum of 90 minutes of illumination for the rated wattage upon loss of AC power. Ideal for applications requiring attractive unit equipment 2 with quick installation Lithonia Lighting - Signature Series Ideal for applications requiring attractive die-cast aluminum signage, superior illumination and low energy consumption Lithonia Lighting Power Sentry battery packs Factory or field installed to operate lamp(s) at an initial output of 10% to 95% of rated lamp lumens, providing optimum glare-free illumination for a minimum of 90 minutes upon interruption of normal power Lithonia Lighting Indura industrial lighting units Provides a minimum of 90 minutes of illumination for the rated wattage upon loss of AC power 6 Reloc Wiring Systems Reloc modular wiring for factories (OnePass) and Offices (Quick-Flex) reduces installation time and allows for adaptation of a space, both during and after construction Synergy Lighting Control Systems Synergy Switchpack A compact and economical lighting control panel that offers simplified solutions for a broad range of lighting control applications. Synergy Lighting Control Systems enhance efficiency and reduce energy costs by controlling the amount of light to meet required illumination levels and limiting light use to occupied spaces Synergy Lighting Control Systems Omni-directional ceiling mount occupancy sensors Ceiling mount sensor heads provide automatic on/off lighting control for indoor applications where an occupancy sensor with a 360 coverage pattern is required. High motion sensitivity and advanced automatically adapting digital circuitry provide install and forget simplicity. Integrated photocell may be used to hold lights off when sufficient daylight is available Synergy Lighting Control Systems Analog Photosensor A low voltage system component that provides ambient light level information to a Synergy or Switchpack lighting control system for use in dimming, switching, or daylighting applications. Also shown with optional canopy, enabling use in outdoor applications Holophane - Petrolux II - 175W to 400W pulse start metal halide - rugged design with borosilicate glass for harsh environments - great vertical illuminance & low brightness ideal for low ceiling spaces - long & narrow distribution for maximum spacing on narrow paths & catwalks - UL listed 40 C and 55 C, damp or wet locations Lithonia Lighting Indura industrial lighting units Similar to above, but NEMA 4X rated for wet location use Lithonia Lighting Extreme vandal-resistant LED exits Ideal for high abuse, cold weather (down to -40 C with CW option), hose-down and wet location applications 16 17

10 multi-national company xyz... Complete lighting solutions for your industrial needs... Lack of proper lighting can lead to higher energy and maintenance cost, decreased productivity and higher cost of quality, and on-the-job injuries. There are many lighting options that are low in initial equipment unit price or low in energy consumption. What truly benefits the environment, employees and corporate profitability are lighting solutions that deliver superior performance and longevity at the lowest total cost of ownership. Acuity Brands Lighting provides, under esteemed brands such as Lithonia and Holophane, both HID and fluorescent lighting systems utilizing state-of-the-art lighting technologies. Acuity Brands Lighting also provides a vast array of products to meet all lighting needs of industrial facilities, from factory floors to warehouse shelves and aisles, desks and corridors in the office space, and parking lots and loading docks. Acuity Brands Lighting s extensive global agency and distributor networks are well trained and strongly backed by the company s International Operations, dedicated to fully serving international customers. The Acuity team lends its expertise to supporting projects in all phases, from specification and lighting audit, to lighting proposal and product delivery. + BEFORE AFTER + renova tion 18 19

11 Providing the industry s broadest line of commercial, industrial, institutional and residential fixtures. A leader in outdoor and industrial lighting solutions for over 108 years. outdoor lighting products sold principally to commercial, industrial, utility, government, and institutional markets. Marketed to energy service companies and energy contractors in the energy saving relighting segment Produces a wide range of lighting control systems, suitable for applications in high-rise office buildings, multi-building complexes, manufacturing plants and sports facilities. Reloc wiring solutions offers plug-in, relocatable components suitable for wiring commercial and industrial lighting fixtures. Reloc modular wiring offers significant benefits over conventional hardwiring, with reductions in installation and labor time as well as easy fixture relocation. Acuity Brands Lighting, Inc. One Lithonia Way, Conyers, GA TEL: WEB: Acuity Lighting Group, Inc. 9/04 Industrial Lighting Renovation: Best Practices Form No Printed on Recycled Paper