Tri Tool Exterior LED Lighting Project

Transcription

1 Tri Tl Exterir LED Lighting Prject ET13SMUD1031 December 22, 2014 Prepared by: Dave Bisbee, CEM Sacrament Municipal Utility District The infrmatin in this reprt is prvided by SMUD as a service t ur custmers. SMUD des nt endrse prducts r manufacturers. Mentin f any particular prduct r manufacturer in this reprt shuld nt be cnstrued as an implied endrsement.

2 CONTENTS 1 EXECUTIVE SUMMARY TECHNOLOGY DESCRIPTIONS LIGHT EMITTING PLASMA Ptential Benefits Imprtant Things t Cnsider HIGH OUTPUT LED FIXTURES Ptential Benefits Imprtant Things t Cnsider WIRELESS CONTROLS PROJECT DESCRIPTIONS BACKGROUND AND OBJECTIVES PROJECT LOCATION: TRI TOOL INC. RANCHO CORDOVA, CA ORIGINAL LIGHTING SYSTEM LIGHT EMITTING PLASMA SYSTEM SUMMARY OF FINDINGS ASSESSMENT OBJECTIVES METHODOLOGY HIGH OUTPUT LED SYSTEM ENERGY MONITORING RESULTS LIGHTING LEVEL MEASUREMENTS ECONOMICS CONCLUSIONS...13 Abut the Custmer Advanced Technlgies Prgram SMUD s Custmer Advanced Technlgies (C.A.T.) prgram wrks with custmers t encurage the use and evaluatin f new r underutilized technlgies. The prgram prvides funding fr custmers in exchange fr mnitring rights. Cmpleted demnstratin prjects include lighting technlgies, light emitting dides (LEDs), indirect/direct evaprative cling, nn - chemical water treatment systems, daylighting and a variety f ther technlgies. Fr mre prgram infrmatin, please visit: The infrmatin, statements, representatins, graphs and data presented in this reprt are prvided by SMUD as a service t ur custmers. SMUD des nt endrse prducts r manufacturers. Mentin f any particular prduct r manufacturer in this reprt shuld nt be cnstrued as an implied endrsement.

3 Tri Tl Exterir LED Lighting Reprt December, EXECUTIVE SUMMARY The engineer reviewed the calculatins ne last time. Sure, LED lighting had made a lt f prgress, but wuld the new fixtures be up t the task? T his knwledge, n ne else in the area had yet tried using LED fixtures munted at 50ft. fr a parking lt applicatin. What if they didn t wrk? Especially since the previus state-f-theart lighting system had just failed. The engineer tk a deep breath and rdered the new fixtures. It is n secret that LED lighting systems have made tremendus prgress during the past three years. Literally thusands f prducts are available fr just abut every applicatin, and dzens f demnstratin prjects have been cmpleted. S what makes this prject ntewrthy? Tw things: (1) 50ft. munting height (2) extending the use f a wireless cntrl system designed primarily fr interir applicatins t a parking lt applicatin. Tri Tl Inc. is n stranger t emerging technlgy research and has participated in several f SMUD s prgrams in the past. In fact, what generated the need fr this prject was the failure f an early generatin light-emitting-plasma system. This reprt describes Tri Tl s three year jurney starting with the riginal high pressure sdium lighting system and ending with the current system which includes high-utput LED fixtures, mtin sensrs and a wireless cntrl system. Like mst demnstratin prjects, we encuntered several bstacles and learned sme valuable lessns alng the way. Summary f Results Overall the final results f this prject were favrable: Estimated energy savings: 76,773 kwh per year (80%) Prject cst (withut research grant): $32,951 Estimated annual cst savings: $9,213 Simple payback: 3.6 years Acknwledgements Figure 1: The new LED fixtures at Tri Tl Inc. were munted at 50ft. abve the grund, which at this time, was cnsidered t be a challenging applicatin fr LED technlgy. Several peple cntributed t the success f this prject including: Jel Waltn (Tri Tl Inc.) Walter Pazik (Glbal Energy Partners) Daniel Mrt (ADM Assciates) Cnnie Samla (SMUD) Leah Pertl (SMUD) The infrmatin, statements, representatins, graphs and data presented in this reprt are prvided by SMUD as a service t ur custmers. SMUD des nt endrse prducts r manufacturers. Mentin f any particular prduct r manufacturer in this reprt shuld nt be cnstrued as an implied endrsement. 2

4 Tri Tl Exterir LED Lighting Reprt December, TECHNOLOGY DESCRIPTIONS 2.1 LIGHT EMITTING PLASMA Originally this prject invlved replacing the existing high pressure sdium (HPS) fixtures with light emitting plasma (LEP) fixtures frm Luxim Inc. The light emitting plasma system cnsists f the cmpnents listed belw and are shwn in Figure 2. These cmpnents are hused within a light fixture (a.k.a. luminaire). The luminaire als includes an ptical assembly t distribute the light prduced by the lamp. Lamp: cnsists f a very small quartz tube (3/4" lng), which cntains a mixture f rare earth halides - similar t cnventinal metal halide lamps. Hwever, unlike cnventinal lamps, the plasma lamp des nt cntain electrdes (mre n this later). Emitter: the plasma lamp is hused within an aluminum assembly specifically designed t cncentrate radi frequency energy within the lamp. Radi frequency (RF) driver: cnnects t the emitter via a cax cable and prduces the radi frequency energy needed t ignite and perate the plasma lamp. AC/ DC pwer supply: cnverts incming line vltage t DC and supplies pwer t the radi frequency driver Ptential Benefits Figure 2: Light emitting plasma system Accrding t the manufacturer, light emitting plasma ffers the fllwing advantages ver cnventinal high intensity discharge lamps: Better reliability: cnventinal metal halide lamps require electrdes within the arc tube (Figure 3). These electrdes are usually made f tungsten and require a mechanical seal - which can lead t premature lamp failure. As the tungsten degrades, it darkens the walls f the lamp and reduces the light utput. Since LEP des nt require the use f electrdes, the reliability and light utput shuld be better than cnventinal metal halide lamps. The infrmatin, statements, representatins, graphs and data presented in this reprt are prvided by SMUD as a service t ur custmers. SMUD des nt endrse prducts r manufacturers. Mentin f any particular prduct r manufacturer in this reprt shuld nt be cnstrued as an implied endrsement. 3

5 Tri Tl Exterir LED Lighting Reprt December, 2014 Rapid start: 45 secnds t reach 80% f full brightness High efficacy: 82 lumens per Watt Better ptical cntrl: since the LEP lamp is nly ¾ lng, it is easier t direct the light where it is needed and prvide even illuminatin levels. Better ptical cntrl is the key t energy savings in utdr lighting applicatins. Faster re-strike: when the pwer is turned ff t high intensity discharge lamps (e.g. metal halide) they require time t cl dwn befre they can be reignited. This is called the restrike perid and can last up t fifteen minutes fr sme lder lamp types. The re-strike perid fr LEP lamps is nly abut 2 minutes much faster than cnventinal metal halide r high pressure sdium systems. Figure 3: Cnventinal metal halide lamps require electrdes within the arc tube a ptential failure pint. LEP des nt require the use f electrdes. Gd clr renditin: the ability f light surces t render clrs accurately is rated by a metric knwn as the Clr Rendering Index (CRI). A CRI f 100 is cnsidered t be ideal. LEP lamps are available with CRI values f 75 and 90. Lnger rated lamp life: 30, CRI and 50, CRI. Nte: unlike high intensity discharge lamps, the rated life fr LEP lamps is nt based upn predicted failures; it is when the lamps are expected t lse 30% f their utput. This is knwn as L 70 life and is the same methd used fr rating the life f LEDs Imprtant Things t Cnsider Like every ther technlgy, there are sme ptential dwnsides t Light Emitting Plasma: Weight: LEP prduces a lt f heat and requires extensive heat sinks, which adds a significant amunt f weight t the light fixtures. Fr example, LUXIM s R400 Radway Luminaire weighs 34 punds slightly mre than cmparable 400 Watt metal halide r high pressure sdium ptins. Care must be taken during retrfits t ensure the existing ples and munting arms will be able t handle the added weight. High Crrelated Clr Temperature (CCT): The light prduced by the LEP systems we tested was blue-greenish white in appearance (5700K) and was nticeably different frm ther light surces. Sme users may find this bjectinable. Limited chice f manufacturers: Since LEP technlgy is relatively new, nly a few manufacturers ffer fixtures with LEP lamps as an ptin. The infrmatin, statements, representatins, graphs and data presented in this reprt are prvided by SMUD as a service t ur custmers. SMUD des nt endrse prducts r manufacturers. Mentin f any particular prduct r manufacturer in this reprt shuld nt be cnstrued as an implied endrsement. 4

6 Tri Tl Exterir LED Lighting Reprt December, 2014 Psitin sensitive: Sme LEP lamps are psitin sensitive and cannt be perated in a face up psitin. Care must be taken t select the prper LEP lamp fr applicatins such as illuminating building façades. Premature failures: Althugh the rated life f LEP lamps is 50,000 hurs, custmers at all three f SMUD s test sites have experienced premature failures. 2.2 HIGH OUTPUT LED FIXTURES Tri Tl selected Cree s high utput EDGE LED fixtures (Figure 4), which have the fllwing rated characteristics: 29,994 initial lumens (120 LEDs driven at 1,000 ma) 426 Watts Efficacy: 70.4 LPW CCT: 4000K CRI: 70 minimum Rated L70 life: 60,000 hurs Five year warranty Dimmable 0-10V LED driver Figure 4: Cree Edge LED fixtures Ptential Benefits Accrding t Cree, their EDGE HO LED fixtures ffer several advantages ver fixtures with cnventinal high intensity discharge lamps: Lnger lamp life: Cree EDGE fixtures are rated t last 60,000 hurs befre lsing 30% f the utput. This cmpares favrably t high pressure sdium lamps which are typically rated fr 24,000 hurs (average failure). Instant n: n restrike r warm up perid required Better ptical cntrl: Cree LEDs are specifically designed and manufactured t precisely direct the light where it is needed and prvide even illuminatin levels. This helps eliminate wasted light and reduce light pllutin. Cntrl friendly: unlike mst exterir HID systems, these LED fixtures are dimmable and are designed t wrk with cntrls that use the ppular 0-10V prtcl. This prvides the pprtunity fr additinal energy savings thrugh the use f mtin-sensr based dimming and ther cntrl strategies. The infrmatin, statements, representatins, graphs and data presented in this reprt are prvided by SMUD as a service t ur custmers. SMUD des nt endrse prducts r manufacturers. Mentin f any particular prduct r manufacturer in this reprt shuld nt be cnstrued as an implied endrsement. 5

7 Tri Tl Exterir LED Lighting Reprt December, 2014 Custmer satisfactin: custmers cnverting frm HPS t LEDs (r ther white light surces) ften reprt increased satisfactin levels. This is likely due t imprvements in clr rendering and appearance Imprtant Things t Cnsider Althugh LED lighting fixtures may ffer several benefits, there are sme imprtant things t keep in mind when cnsidering using them in exterir lighting applicatins: Lwer efficacy at higher drive currents: using LED fixtures at higher munting heights (i.e. > 30ft.) usually requires perating the LEDs at higher drive currents. Fr example, the efficacy f the EDGE HO LED fixtures ranges frm ma t ma. Weight: since LEDs are electrnic devices, they require heat sinks which add a significant amunt f weight t the light fixtures. This is especially true fr LEDs perated at higher drive currents. Fr example, the EDGE HO fixture with 120 LEDs weighs 45 lbs. while the 240 LED ptin weighs in at a hefty 80 lbs. Care must be taken during retrfits t ensure the existing ples and munting arms will be able t handle the added weight. Cst: fr applicatins that require higher illuminatin levels, LED fixtures ften cst tw t three times mre than traditinal HID ptins. 2.3 WIRELESS CONTROLS In 2012, Tri Tl retrfitted all f their ffice spaces and sme f their prductin areas with LED fixtures and Daintree Netwrks wireless cntrls. Daintree s system uses multiple cntrl devices and the ZigBee wireless cmmunicatin standard t frm a wireless mesh netwrk as shwn in Figure 5 (next page). Since Daintree s cntrl devices use lw pwer signals t cmmunicate, they are primarily designed fr interir applicatins. Advanced lighting cntrls (such as Daintree) ffer several capabilities including: Task tuning: allws the users t adjust the lighting levels accrding t their needs and avid having unneeded, ver-lit areas. Task Tuning typically saves 20-30%. Energy tracking: ability t track energy usage, csts and savings in real-time. Web-based cntrl: ability t cntrl lighting n-site r remtely frm internet-based interfaces, such as smart phnes r wireless cmputers. Users may create simple perating schedules r implement advanced cntrl strategies such as mtin-sensr based dimming. The infrmatin, statements, representatins, graphs and data presented in this reprt are prvided by SMUD as a service t ur custmers. SMUD des nt endrse prducts r manufacturers. Mentin f any particular prduct r manufacturer in this reprt shuld nt be cnstrued as an implied endrsement. 6

8 Tri Tl Exterir LED Lighting Reprt December, 2014 Figure 5: Daintree s wireless mesh netwrk Tri Tl cntrlled the LED fixtures thrugh the use f Daintree Wireless Adapters (WA100s) and Wattstpper HB350W-L3 mtin sensrs. These cmpnents were field installed by Tri Tl s electricians. The infrmatin, statements, representatins, graphs and data presented in this reprt are prvided by SMUD as a service t ur custmers. SMUD des nt endrse prducts r manufacturers. Mentin f any particular prduct r manufacturer in this reprt shuld nt be cnstrued as an implied endrsement. 7

9 Tri Tl Exterir LED Lighting Reprt December, PROJECT DESCRIPTIONS 3.1 BACKGROUND AND OBJECTIVES The riginal purpse f this study was t evaluate the field perfrmance and cst effectiveness f Luxim s light emitting plasma technlgy in a high mast, exterir lighting applicatin. Objectives included gathering the necessary data t cmpare illuminatin levels, energy cnsumptin and Tri Tl s perceptin f the LEP technlgy. When this prject began (early 2011), LED technlgy was nt yet cnsidered t be a viable ptin fr applicatins with munting heights f anything ver 30 feet. Hwever, due t excessive failures, Tri Tl chse t replace the light emitting plasma fixtures with high utput LED fixtures in 2013 (Figure 6). Cnsequently, this study was expanded t include the perfrmance f the riginal HPS system, the LEP system and the high utput LED system. Figure 6: when the LEP fixtures failed prematurely, they were replaced with high utput LED fixtures 3.2 PROJECT LOCATION: TRI TOOL INC. RANCHO CORDOVA, CA Fr ver 40 years, Tri Tl Inc. has been the wrld s leading designer and manufacturer f precisin prtable machine tls fr pipe beveling, tube squaring and severing, clamshells fr in-line cutting, and flange facing equipment. Tri Tl als prduces heavy-duty pipeline machinery, prvides custm machinery design and manufacturing, n-site machining and welding services, and ffers equipment rental ptins. 3.3 ORIGINAL LIGHTING SYSTEM The riginal lighting system cnsisted f twenty-three, shebx type fixtures with 1,000-Watt high pressure sdium lamps. The fixtures were munted n 50 ft. ples and were cntrlled via a time clck set fr dusk t dawn peratin. Befre Tri Tl mved int this facility, it was used as a secure gvernment strage site. Cnsequently, the measured illuminatin levels in the parking lt were excessively high (Figure 7). The infrmatin, statements, representatins, graphs and data presented in this reprt are prvided by SMUD as a service t ur custmers. SMUD des nt endrse prducts r manufacturers. Mentin f any particular prduct r manufacturer in this reprt shuld nt be cnstrued as an implied endrsement. 8

10 Tri Tl Exterir LED Lighting Reprt December, 2014 The measured illuminatin levels fr the high pressure sdium lights were: Average: fc Maximum: 23.8 fc Minimum: 7.65 fc Max/Min: 3.11 Max/Ave: 1.49 The riginal HPS lighting system cnsumed an estimated 96,554 kwh per year. Althugh Tri Tl wanted t upgrade their lighting system, few viable ptins were available since their fixtures were munted at 50ft. abve the grund. 3.4 LIGHT EMITTING PLASMA SYSTEM In Octber f 2011, Tri Tl decided t replace their existing system with Luxim s R400 Light Emitting Plasma (LEP) fixtures (Figure 8). At first the results were very psitive. Even thugh the illuminatin levels were much lwer than prvided by the HPS lights, Tri Tl was very pleased with the imprved clr rendering and was lking frward t the predicted 75% energy savings. Unfrtunately, the LEP fixtures failed prematurely and had t be replaced. The initial measured illuminatin levels were as fllws: Average: 2.84 fc Maximum: 4.12 fc Minimum: 1.66 fc Max/Min: 2.48 Max/Ave: 1.45 Figure 7: the riginal illuminatin levels were excessively high! Figure 8: Ratings fr Luxim s light emitting plasma fixtures The infrmatin, statements, representatins, graphs and data presented in this reprt are prvided by SMUD as a service t ur custmers. SMUD des nt endrse prducts r manufacturers. Mentin f any particular prduct r manufacturer in this reprt shuld nt be cnstrued as an implied endrsement. 9

11 Tri Tl Exterir LED Lighting Reprt December, SUMMARY OF FINDINGS 4.1 ASSESSMENT OBJECTIVES SMUD hired ADM t mnitr the LED lighting system and calculate the annual energy savings cmpared t the riginal HPS system. Cmmissining the lighting cntrls turned ut t be a difficult, drawn-ut prcess. Cnsequently, ADM mnitred the parking lt lighting energy use fr nearly ne year. 4.2 METHODOLOGY Lighting pwer cnsumptin was measured at the breaker panel using an Enernet K20 multi-channel pwer lgger. High accuracy split-cre current transducers (CTs) were placed inside the electrical panel (Figure 9). The system was set t recrd energy use in 2-minute intervals and the lgger wuld hld 27 days f data. Mnitring started after the LEDs and cntrls were installed. Hwever, since the cntrl strategies were changed several times t address prblems, the mnitring perid lasted nearly ne year. In rder t separate the savings resulting frm the cntrls, the mnitring data was rganized int three categries: 1. HPS baseline perid: the riginal high pressure sdium lights perating frm dusk t dawn. 2. LED baseline: the new LED lights perating frm dusk t dawn. 3. LED with cntrls: new LED lights with the wireless cntrls activated Figure 9: Split-cre transducers were placed in the electrical breaker panel t measure the lighting system energy cnsumptin. The infrmatin, statements, representatins, graphs and data presented in this reprt are prvided by SMUD as a service t ur custmers. SMUD des nt endrse prducts r manufacturers. Mentin f any particular prduct r manufacturer in this reprt shuld nt be cnstrued as an implied endrsement. 10

12 Tri Tl Exterir LED Lighting Reprt December, HIGH OUTPUT LED SYSTEM In June f 2013, Tri Tl replaced all twenty-ne light emitting plasma fixtures with high utput LED fixtures (Figure 10). Each new fixture included ple munted mtin sensrs and Daintree wireless cntrls. The parking lt lights perated apprximately 4,600 hurs per year r 52% f the time. The Daintree system uses ZigBee wireless cmmunicatins t cntrl each light ple. Daintree s sftware incrprates an astrlgical time clck and feedback frm the mtin sensrs t adjust the lighting level t reduce energy use. Initially Tri Tl s Facility Manager was very enthusiastic abut the system and implemented sme very sphisticated cntrl strategies. Unfrtunately, these initial strategies did nt pan ut, due t a bug in the sftware which caused lights t turn ff when they shuld nt be ff. After several unsuccessful attempts t slve this prblem, Tri Tl s Facility Manager implemented a much simpler, yet still effective, cntrl strategy which is shwn belw in Figure 10. Figure 10: Tri Tl parking lt cntrl strategies 4.4 ENERGY MONITORING RESULTS ADM mnitred the parking lt lighting frm Nvember 7, 2013 thrugh Octber 13, Data was cllected several times during the year t gather infrmatin fllwing changes in the cntrl strategies. The data was rganized int three different categries: 1. Original high pressure sdium fixtures (1000W HPS) 2. LED fixtures cntrlled nly by a time clck (LEDs Full ON) 3. LED fixtures with wireless cntrls activated (Cntrlled LEDs) The infrmatin, statements, representatins, graphs and data presented in this reprt are prvided by SMUD as a service t ur custmers. SMUD des nt endrse prducts r manufacturers. Mentin f any particular prduct r manufacturer in this reprt shuld nt be cnstrued as an implied endrsement. 11

13 Tri Tl Exterir LED Lighting Reprt December, 2014 The tabulatin f annual energy use fr the three lighting situatins is shwn in Figure 11 and Fixture 12. The savings when cmparing these situatins are shwn in Figure 13. The savings fr the new LED parking lt lights and cntrls versus the riginal HPS lighting is a very substantial 80%. Sme f this savings is due t the fact that the riginal lights were much higher wattage than necessary (as evidenced by the extrardinarily high illuminatin levels). If Tri Tl had been able t use the mtin sensr cntrls during the mrning and evening hurs, the savings culd have been even higher. Figure 11: Annual energy cnsumptin graph Figure 12: annual energy cnsumptin Figure 13: Lighting system cmparisn 4.5 LIGHTING LEVEL MEASUREMENTS Light level measurements were made under several ples ne night in Nvember Apprximately ten feet away frm the ple the light levels ranged frm 1.4 t 2.0 ftcandles when the lights were at 55%. 4.6 ECONOMICS The cst f lighting systems using new technlgy is ften expensive, smetimes simply because the ecnmics f vlume manufacturing has nt kicked in. The cst f material and installatin fr this case study was $32,951. Using an average f $0.12/kWh the 76,773 kwh in annual energy savings translates t $9,213 per year. The custmer s simple payback is 3.6 years. The infrmatin, statements, representatins, graphs and data presented in this reprt are prvided by SMUD as a service t ur custmers. SMUD des nt endrse prducts r manufacturers. Mentin f any particular prduct r manufacturer in this reprt shuld nt be cnstrued as an implied endrsement. 12

14 Tri Tl Exterir LED Lighting Reprt December, CONCLUSIONS Three years ag, SMUD began wrking with Tri Tl t assess the perfrmance f Luxim s light emitting plasma (LEP) system. Hwever, due t excessive prduct failures, Tri Tl replaced the LEP fixtures with high utput LED fixtures and Daintree wireless cntrls. Ultimately the results f this study were mixed: Benefits Energy savings f 80% (cmpared t the riginal HPS system) Annual cst savings f $9,213 per year Simple financial payback f 3.6 years Psitive feedback frm Tri Tl emplyees regarding the imprved appearance and lighting quality Challenges Premature failures f the light emitting plasma fixtures Difficulty cmmissining the cntrls and sftware Since this study began, LED prducts have imprved dramatically. Custmers can nw have cnfidence using LED fixtures fr parking lts with fixture munting heights f 50ft. and perhaps even higher. Hwever, mre wrk may be needed in the area f lighting cntrls especially using mtin sensrs at heights abve 20 feet. SMUD wishes t nce again thank the peple at Tri Tl Inc. fr their pineering spirit. The infrmatin, statements, representatins, graphs and data presented in this reprt are prvided by SMUD as a service t ur custmers. SMUD des nt endrse prducts r manufacturers. Mentin f any particular prduct r manufacturer in this reprt shuld nt be cnstrued as an implied endrsement. 13