Lighting in Cold Storage Aaron Kless, PE Director of Application Engineering Digital Lumens Agenda Energy Usage in Cold Storage Lighting Energy and Heat Load Lighting Technology Alternatives Case Study Ardo, UK 2
Typical Cold Storage Energy Profile Where is the energy going? Battery Charging Exhaust Fans/Misc Equipment Office HVAC Lighting Refrigeration Electric Defrost 3 SOURCE: A. Lekov, L. Thompson, A. McKane, A. Rockoff, M.A. Piette, Opportunities for Energy Efficiency and Automated Demand Response in Industrial Refrigerated Warehouses in California (2009), Lawrence Berkeley National Laboratory Typical Heat Loads Typical Heat Loads on Refrigeration System include: Product Transmission Infiltration Defrost Internal Generation personnel, lights, other equipment 4 12/29/10
Energy Balance - Lighting Electric Energy Heat Energy Sound Energy Light Energy Light is absorbed by product and structure and re-radiated as heat energy this becomes chiller load Load on Refrigeration System Number of Lights 100 Light Fixture Power (HPS) Total Lighting Power Total Lighting Power (BTU/hr) Max Refrigeration Load 465 W 46.5 kw 158,658 BTU/hr 13.2 Tons Refrigeration Assuming steady state operation, 90% Load Factor The chiller will have to remove 1.25 billion BTUs of energy each year from the lights alone - enough energy to melt over 4,300 tons of ice! 6
How Much Are You Spending To Remove Heat From Lights? Typical Coefficient of Performance (COP) for Industrial Refrigeration System is 2-5 COP = [(heat energy removed)/(system energy input)] Upgrading the lighting system results in direct savings from lighting energy usage reduction and real additional savings for heat load reduction 7 Lighting Alternatives Lower energy alternatives include HIF, LED, and LED with intelligent controls The key to significant energy usage reduction in cold storage is taking advantage of control systems HVAC & chiller load reduction Fine-tuning Intelligent Lighting System Incentives Savings Summary LED power reduction (watts) 8 Maintenance Intelligence
Fine Tuning Controls Motion Sensor timeout has a significant impact on energy savings Shorter timeouts drive greater savings Low time threshold is technology driven Solid state lighting lifetime not affected by excessive cycling 9 Sensor Settings & Energy Cost: Integrated System Maximizes Savings Sensor Delays and Energy Savings Sensor Delay % Active ILE Energy Cost* (160W) HIF Energy Cost* @ 15 mins (220W) 30 sec 25.2 % 27.13 147.29 60 sec 40.8 % 44.19 147.29 90 sec 52.4 % 56.59 147.29 3 min 72.5 % 79.07 147.29 5 min 89.3 % 96.90 147.29 10 min 98.6 % 106.98 147.29 4:30pm 5:30pm * 10 /kwh
Case Study Ardo, UK Frozen Vegetable Distribution Center 80,000 cubic meters Movable racking system -27 C 7,000 operating hours/year 165 x 400W High Pressure Sodium Fittings (456 W) 11 Case Study Ardo, UK Solution: Digital Lumens Intelligent LED Lighting System installed in July of 2012 165 x 160W ILE HB-3 fixtures with LightRules control and monitoring system Motion sensor and wireless controls integrated into every fixture 12
Case Study Ardo, UK Occupancy data from LightRules system: Average Occupancy, Week of 27 Sep 3.11% Average Weekly Occupancy 9% 13 Overview Presentation Case Study Ardo, UK Analysis from LightRules system: Extending motion sensor timeout from one minute to fifteen minutes would drive light usage up by over 2.5 times Short sensor timeout drives significant savings 14 Overview Presentation
Case Study Ardo, UK Usage Summary: Previous (HPS) Current (LED) Annual Direct Lighting Energy Usage 540,000 kwh 20,200 kwh Annual Lighting Heat Load 1.8 x 10 9 BTU 6.9 x 10 7 BTU 15 Case Study Ardo, UK Project Summary: Total Annual Energy Savings 750,000 kwh Tonnes CO 2 Saved Annually 400 Simple Payback 1.8 years 97% Total Energy Savings 16
Digital Lumens: Tested & Proven Deployed in the world s leading industrial facilities Cold Storage, Warehouses, Manufacturing, etc. More than 200 large-scale deployments 17 Summary Energy Usage in Cold Storage Lighting Energy and Heat Load Lighting Technology Alternatives Case Study Ardo, UK 18
Questions? 19 Thank You Aaron Kless, PE akless@digitallumens.com support@digitallumens.com