Energy Efficient Industrial Lighting
Roy Hughes, PEng, LC
• Energy Efficient Lighting Design • Dynamic Lighting Controls• New Technologies – Efficient Lighting• Future Vision
Energy Efficient Industrial Lighting
Lighting Design for Industry
Lighting can:
Allow for visual function
Critical Seeing Tasks
Lighting can:• Allow for visual function• Support the
Architectural Vision
Lighting can:
• Allow for visual function• Support the
Architectural Vision• Complement Form
Lighting can:
• Allow for visual function• Support the
Architectural Vision• Complement Form• Create visual
hierarchies• Direct the Eye
Lighting can:
• Allow for visual function• Support the
Architectural Vision• Complement Form• Create visual
hierarchies• Direct the Eye• Assist way-finding
Lighting can:• Allow for visual function• Support the
Architectural Vision• Complement Form• Create visual
hierarchies• Direct the Eye• Assist way-finding• Be dynamic
Lighting can:• Allow for visual function• Support the
Architectural Vision• Complement Form• Create visual
hierarchies• Direct the Eye• Assist way-finding• Be dynamic• Extend the work day
Lighting can:• Allow for visual function• Support the Architectural
Vision• Complement Form• Create visual hierarchies• Direct the Eye• Assist way-finding• Be dynamic• Extend the day• Transform spaces
Updated IESNA Standards
• ANSI/IESNA RP - 7- 01
• Recommended Practice for
Industrial Lighting
Daylight
– People like daylight– Improves productivity– Improves mood– Saves Energy
Diffusing skylights spread soft daylight evenly across this library space.
Photo credit SunOptics Skylights
Bringing Daylight Inside• SunPipe
It looks like an electric light, but is actually all daylight!
Available for Commercial/Industrial as well as Residential applications
Energy Efficient Industrial Lighting
• Dynamic Lighting Controls• New Technologies - Efficient Lighting
• Future Vision
• Manual zoned/ dimmed• Automatic - Occupancy
– Infrared/ Ultrasonic/ Dual sensors
– Time clocks– Timers
• Automatic - Light Levels– Photo cells (measured)– Load reactive (peak)– Time clock (predicted)
Dynamic/Controlled Lighting
Integrate the Lighting Controls
Wireless Lighting Controls• ZigBee Mesh Networking
– Microprocessor based devices with embedded radios– Lighting Ballasts become control and communication
nodes– Utilizes an open protocol for communication – ZigBee– Mesh Network - Scalable, flexible up to 65,000 network
nodes– 100% digital component based network of devices with
the lighting infrastructure providing the DLN backbone– Software and UI’s determine the user experience– Distributed control of lighting – From personal space to
enterprise control
Reduced cost and complexity of system installation
Simplicity of Commissioning
Simplify Lighting Control System design in both new construction and retrofit applications
Key value drivers of a Wireless Lighting Control system
Easy and intuitive to use facilitating improved worker productivity
Operating cost and complexity reductions
Improved energy management and control
Key value drivers of a Wireless Lighting Control system
Motion Vibration
Solar TemperatureDifferential
Self Powered switches and sensorsHarvesting Energy from
Everyday activities!
The mechanical push of a button and solar power is enough to power transmissions, 30M indoors through walls and 300M outdoors.
Switches & Sensors are Wireless
Wireless Motion Detection
Wireless SwitchWireless Thermostat
Room Controller
Wireless Humidity
Lights on/off - Dim up/down
Wireless Light Detection
Heat up/down - A/C on/off
Wireless Daylight Harvesting Control
• maximizes energy conservation using the principals of manual on, dimming, and auto off technology.
• in no time at all, retrofit your classroom, hospital room, office with a wireless self powered switch and photo sensor and a dimming controller designed to maintain the perfect light level by dimming down or turning off the lights.
• occupancy sensor available.
TM
Adaptive Lighting
Prince George Pilot ProjectPrince George Pilot Project
Located in Prince George, BC. 69 Luminaires were retrofitted with Adaptive Lighting controls on 2.5 km main arterial, commercial and
residential roadway. Transit line is operational until 8 p.m. with varying pedestrian conflict levels.
Annual Savings this Project (170 Luminaries)
47,000 kWh ($3100)Payback = 7 Years (worst case)
(Assuming $0.066 per kWh)
15th Street, a main arterial roadway in Prince George, BC. retrofit 171 Luminaires with new innovative technology on 2.5 km main arterial with commercial and residential roadway. Transit line operational until 8 p.m. with varying pedestrian conflict levels.Lighting was dimmed to 70% or 50% depending on changes in traffic patterns.
Prince George Pilot ProjectEnergy Savings
Dynamic Lighting Opportunities
Control/ call Centers
No wired switches
Industry
Inspection tasks
• Energy Efficient Lighting • Dynamic Lighting Controls• New Technologies - Efficient Lighting• Future Vision
What’s New in Lighting
Lamp Efficacy* Continues to Improve* the ratio of light out to power in lumens per watt.
• Incandescent - 5 to 20 l/w
• Halogen -15 to 35 l/w
• CFL - 20 to 80 l/w
• Fluorescent - 60 to 100 l/w
• HID - 25 to 130 l/w
• LED - 25 to 80 l/w
Lamp Life is Improving• Halogen
– 3500 to 5000 hrs
• CFL– 6000 to 18,000 hrs
• Fluorescent– 20,000 - 40,000 hrs
• HID– 6,000 to 40,000 hrs
• Induction & LED– 50,000 - 100,000 hrs
Lamp Lumen Depreciation Improves“The fractional loss of lamp lumens at rated operating conditions that progressively
occurs during lamp operation. ” IESNA
75
80
85
90
95
100
0 20 40 60 80 100Percent of Average Rated Life
% o
f Ini
tial L
umen
s
T5
T8 (265 mA)
Incandescnt
T12 (430mA)HPS
MercuryVapor
Improvements to incandescent• Lamp Filament
Design– Including HIR
technology• Reflector Design
– Shape and coatings• Bulb Coatings
– Improved colour• Gas Fill
– Krypton gas
• “Retail HIR”, new lamps combine a silver-coated reflector thin film HIR™technology. – 33% longer life and – 30% energy savings – 50% less heat in the beam.
• replace a 90PAR lamp with a 55PAR HIR lamp
…with no reduction in lumens
Improvements in Incandescent
Halogen to LED replacements
4.8 Watts 150 Lumens
20W equivalent (120V)Warm or cool white
4.5 W 4.5 W 150 Lumens150 Lumens
20W equivalent (12V 20W equivalent (12V -- 24V)24V)Warm or cool whiteWarm or cool white
11W R30 LED11W R30 LED500 Lumens500 Lumens
60W equivalent (120V)60W equivalent (120V)Warm or cool whiteWarm or cool white
• Pulse Start Technology - matures• Ceramic Metal Halide – more products
– from 20 to 400 Watts – Colour control rivaling fluorescent– Various shapes - single ended to PAR
Improvements to HID LampsImprovements to HID Lamps
Ceramic Metal Halide• Less colour shift• Lamp life shorter than HPS• Cold starting down to -12c• Orientation sensitive (V/H/U)
• Improved efficacy - L/W• Excellent CRI - 90 to 95%• Light output still drops off
over life - better than standard
Ceramic Metal Halide - improved arc tube
320 Watt replaces 400 Watt MH
320W POWERBALL®
The Best of the Best
0%
20%
40%
60%
80%
100%
120%
140%
320WPOWERBALL
M400/U MP400/PS BU-ONLY
MS400/PS BU-ONLY
Relative Mean Light Output Relative Wattage
Ceramic Metal Halide
Ceramic MH screw-in PAR38
• 3x less energy than standard PAR38 halogen lamps
• 10,500 hours rated life • 1220 initial lumens • 87 CRI for true color
rendition • Available in beam spreads
of 10º, 25º, & 40º• Easy upgrade and instant
retrofit for halogen PAR38
• “White” Light - less colour shift• Extreme high efficiency -• Universal burning position• Compact size – 50% smaller• Improved efficacy – 103 L/W• CRI - 66%• 2730K CCT
New generation Ceramic MH
60 Watt 6800 lumens
A New Generation of Outdoor Lighting
One new Lamp Category: “electronics only”Dedicated Electronic Ballast Platforms
New Lamp Family
Ballast Comparison
140W CPO-T Electronic
154 Watts
10%
Yes
150W HPS Type CWA
195 Watts
30%
Limited
Input
Losses
Dimmable
A New Age in Urban Outdoor
Lighting….
Optics+Luminaires
E-Ballast
SystemDevelopment
Lamps
CosmoWhite
A compact system of a lamp, socket, and ballast, specially designed for outdoor applications
Improvements to Fluorescent• Lamp Life
– More long life options• Colour Rendering
– 85 CRI or better• Colour Temperature
– Higher CCT available• Lumen Maintenance
– More light over life
Fluorescent Lamp size issues
• Cool White T12– 70 lpw– 62 CRI– flicker with magnetic
ballast– 20,000 hr rated life– LLD: 60 to 70%
• T8 / 80– 92 lpw– 85 CRI– Imperceptible lamp
flicker with electronic ballast
– 20,000 hr rated life– LLD: 80 to 90%– Better optical package
T-12T-8
T-5
• T5 / 80– 93(HO) – 104 lpw– 85 CRI– Imperceptible lamp flicker
with electronic program start ballast
– 20,000 hr rated life– LLD: 90 to 95%
– Best optical package
Do we have enough T8 lamps? - 97 choices!
2700 3000 3500 4100 5000 6500F32T8/25/8xx 2 2 2 2F32T8/28/8xx 3 3 3 2F32T8/30/8xx 3 3 3 2F32T8/30/8xx/long life 1 1 1 1F32T8/7xx 3 3 3 2 2F32T8/7xx/long life 2 2 2 1F32T8/8xx 3 3 3 3F32T8/8xx/long life 1 3 3 3 3 3F32T8/8xx/extra long life 1 1 1F32T8/8xx/HP 3 3 3 2F32T8/9xx 1
T8 Energy Saving - 25W• operate on instant start
ballast • Replace existing 32W
T8 lamps for an immediate savings of 7 watts - 25% energy savings.
• Replacing F34T12 magnetic systems with 25W T8 on Instant Ballast can savings of up to 60 watts/luminaire - or 40% energy savings.
High-Lumen T8 lamps
• “Premium / Super / Enhanced”• Produce 3100 initial lumens or more
• Maintain 2915 or greater mean lumens
• Slightly higher L/W than standard T8 (91 vs. 88)
• Provide 85 or greater Color Rendering Index
• Achieve a rated life of 30,000 hours or greater
Long life T8s
• 224 Watts replaces 455 Watts - 20% more light
• Better Quality - Control, Color and CRI - No Color Shift Lower Maintenance Costs - Replacement Material Lasts Longer and Costs Less
• Extra Features -Dimming, Occupancy Sensor, and Emergency Options
High Efficient FluorescentHigh Efficient Fluorescent
New T-5 properties• High Efficacy 100+ l/w• Low wattage 28• 5/8” profile optimizes fixture
performance.• Small diameter for smaller
fixture size.• Low LLD, 95%• T-5 High Output (HO)
– High surface brightness (glare)
– Can be a challenge to uniformity
Metal Halide Pulse Start Vs T5HO Fluorescent
0
5,000
10,000
15,000
20,000
25,000
30,000
35,000
40,000
45,000
0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000Hours
Lum
ens
Standard400WPulse StartMetalHalideVenture320WPulse StartMetalHalideT5 HO 3Lamps perLuminaire
Lamp Lumen Depreciation
Improved Amalgam Technology
• More light output over a wider temperature range
• 90% light output from 5C to 75C
• New amalgam technology reduces warm-up time
• Quicker run-up to full brightness
Improved Amalgam Technology
Compact fluorescent lighting• Energy savings of 70-75% vs.
incandescent bulbs• Eight to ten times longer life• Huge implications when employed
on a larger scale
CFL Technology continues to mature• Lamps more like
incandescent - 80% energy saving
• New High Wattage CFL’s for industrial and commercial applications
• 1Watt to 200Watts
CFL Technology large lamps• 57W and 70W Plug-in• 42,000 - 53,000
Lumens• Approx. 7in - 8in
length• up to 200 Watts
High Lumen CFL’s
Courtesy: 1st Source, Sportlight, Lightedge, Metalux, Day-Brite
Alternative Low & High
Bay Luminaires
Induction Fluorescent
Compact Fluorescent
T8 or T5HO Fluorescen
t
Hill Air Force Base
High Wattage CFL
Courtesy: Sportlight
•High CRI•Instant start•Step Switched CFL Low Bay luminaires•(8) 10,000 hr lamps
•Plentiful Daylight•Photo Controls•Step Switched Biax CFL Low Bay luminaires•(8) 20,000 hr lamps
High Wattage CFL
Electrodeless Induction Lamps
• 100,000 hour lamp life• 70 lumens per Watt• Cold start to - 30 °C• instant re-strike• RE phosphors • 80+ CRI• Various color temps
Electrodeless Linear Induction• Lamp and ballast system
100,000 hour rated life• Instant on/instant restrike • 3500K and 4100K color
temperatures • 80 CRI • Starting down to - 40°C • 70% lumen maintenance at
60,000 hours ICETRON™
Courtesy: 1st Source,
•High CRI•Instant start•Step Switched Induction Low Bay luminaires•(2) 100,000 hr lamps Induction Lamps
• Principles of Energy Efficient Lighting Design
• Dynamic Lighting Design• Using Newer Technology for Efficient
Lighting• Case Studies in the Industrial Sector• What’s next?
Case study: Warehouse
• 320,000 square-foot warehouse originally lit with HID lamps, upgraded lighting to high-output T5 fluorescent lamps. Retrofit yielded consistent lighting levels, high color rendering and energy reduction of 36%.
Case study: Industrial Shop
• Industrial assembly plant originally lit with 400W HID lamps, upgraded lighting to 4 high-output T5 fluorescent lamps (240W). Lighting controls (occupancy sensors) included in the luminaires allow for additional energy savings where areas are unoccupied.
Case study: School gymnasium
• Gymnasium originally lit with HID lamps, directly replaced with 2’x4’ 6-lamp F32 T8 fluorescent lamps. Retrofit yielded brighter and whiter lighter output with energy reduction of 52%.
Arena - Before - T12HO and 2x400W Metal Halide
Arena - After – T8 HBF
Gym -Before - Metal Halide and Incandescent - low illumination.
Gym - After – T5HO and occ. sensors
Gym - Before – Combination MH+HPS
Gym - After – T5HO and occ. sensors
Gym - Before – HPS
Gym - Before – HPSGym - After – T5HO
Classroom - Before –T8 luminaires mounted too high- dark and non-unifo
Classroom - After –T8 but lowered – brighter- more uniform
Improvements to Ballast TechnologyImprovements to Ballast TechnologyThe Future is Electronic....Why?
Compact size
Performance:
Constant wattage
Energy efficiency & Economics
Controllability
High-Performance Electronic Ballasts
2 F32T8
Watts BF Watts BF Watts BF Watts BF Watts BFlow 50 0.77 48 0.78 48 0.77 48 0.78 47 0.77
lpwnormal 58 0.88 55 0.88 54 0.87 55 0.88 54 0.87
lpwhigh 77 1.16 73 1.18 74 1.15 74 1.20 NA -
lpw 89 95 92 96
97
89 94 95 94 95
90 96 95 96
ULTim8Standard ballasts
UltraMax/StartOptanium QHE / QTP
Electronic Fluorescent ballasts
1 & 2 lamp High Ballast Factor Electronic Ballasts deliver 36%36%more light than standard T8 systems. 2 - 32W lamps with 1.18BF ballast provide the samesame light output as a 3-lamp standard T8 system 2 - 32W lamps with 0.77BF ballast provide the samesame light output as a 2- 40W lamps, T12 system
Features:
1 & 2 lamp ballasts now available
low harmonic distortion (<10% THD).
5 year warranty
Electronic HID Ballasts
• 20 Watt to 200 Watt Metal Halide and HPS
• Multiple voltages –120 to 277V
• Constant colour• Improved regulation
Smaller, lighter ballasts lead to smaller, lighter luminaires– Smaller (less expensive?) enclosures– Less prone to vibration effects
(particularly for exterior)
2.5 lbs7 lbs
400W MH Lumen Maintenance400W MH Lumen Maintenance
Improved LLD = More Light = Fewer Luminaires
10,00015,00020,00025,00030,00035,00040,00045,000
4K 8K 12K 16K 20K100HOURS
LIG
HT
OU
TPU
T (lu
men
s)
Standard MH
Pulse Start MH
Affect of ElectronicBallast
HID Electronic ballasts
- 462 watts
- 400 watts
- 375 watts
HID Electronic Ballasts Lamp Life -improving
Changes to LEDChanges to LED’’ssMore products
more sizes and shapes
lower prices
higher efficiencies
better “white” LED’s
Light Emitting Diodes
•Solid State Light Source•Extremely Flexible•Potentially Long Lamp Life•Dynamic Color Opportunities•Poor White Color Rendering
Courtesy: Color Kinetics, Lumileds, Nichia
0
25
50
75
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1970 1980 1990 2000 2010 2020
Accelerated R&D for White Light SSL
Metal Halide Pulse start
T-8 lampT-12 ES
MonoOLED
T-12 fluorescent
MonoLED
White Light SSLLaboratory
Effi
cacy
(lum
ens
per w
att)
White Light SSLCommercial
SSL Laboratory and Commercial Curves, revised May 2006Year
Conventional Lighting Technologies Potential Growth
for Conventional Light Sources
http://www.netl.doe.gov/ssl/publications.htmlhttp://www.netl.doe.gov/ssl/publications.html
Energy Efficiency of White LEDsEnergy Efficiency of White LEDs
What do White LEDs cost?What do White LEDs cost?White LEDWhite LED’’s cost significantly more than traditional light sourcess cost significantly more than traditional light sources
Light Source Cost per 1000 Lumens
White LED $50.00
Incandescent $ 1.00
CFL $ 5.00
http://www.netl.doe.gov/ssl/publications.htmlhttp://www.netl.doe.gov/ssl/publications.html
Can LEDs finally replace conventional lamps?
IntelliWhite™ iW MR is • LED to retrofit standard
MR16 lamps• compatible with most
dimmers and transformers designed for use with incandescent 12 volt lighting systems
• 3000K, 3500K & 6500K
Color Kinetics• eW™ MR is a compact
lamp designed to retrofit into most standard MR16 fixtures and sockets. It is well suited for use with tracks, rails, cables, and pendants in interior architectural, retail, exhibit, and display applications.
• 2700K and 4200K and two beam angles: 10°and 25°.
• 7.3 to 13.8 lm/W• Not for use on Electric
Transformers
LumeLEX Series• Output of 1000 lumens,
equivalent to 75 watt • Dimming from 100% to
10% without color shift• 50,000 hour life• 35 watts total power • No UV or IR in beam• 28.5 lm/w
Application Efficiency
• Inherent directionality of the LED light source
• Lower fixture losses compared to bulb-shaped lamps
• More delivered illuminance for lower total lumens and lower energy consumption
Half of the light is lost in the fixture
LRC
PNNL
LED Roadway Light
Beta – The EDGE
Hankey Asia Ltd.
More Outdoor LED Luminaires
Municipal Garage Project• Commercially available LED lighting• 1:1 Retrofit of one floor of a parking structure• Delivering >40% total power savings
• Plus: Where would you rather walk at night?
LED Lights supplied by Lighting Science Group
www.ledcity.org
LED excels for low light applications
• especially where you can use colour
LED excels for specialty applications
Selection of promising near-term commercial applications
(there are many others)
• Linear by Lucere Lighting– 18 watts– Available through sales reps
Winner – Undercabinet
• Halley by Lucesco– 19 watts; dimmable
Winner – Portable desk/task
Downlights
Permlight Prescolite Progress Lighting
New on the marketLED Lighting Fixtures, Inc. (LLF)
Refrigerated Case Lights
Lumination (GELcore)
Nualight
Low Bay
Lighting Sciences
Before
After
City of Raleigh Municipal Parking Deck – Part of LED City Project
42 Watt LED replaces 175 Watt MH
42 Watt replaces 150 Watt HPS
LED Lighting
Outdoor Area/StreetlightingToronto Demonstration
Leotek Electronics
What changes are coming?
• Higher current and temperature tolerances• Better color quality and metrics• Better luminaire design• New standards
• Dynamic Lighting Controls• New Technologies for more Efficient
Lighting• Future Vision
Roadmap to Energy Efficiency- what are our options!
UBC Solar Canopy Project
Inside Solar Canopy Project
Solar Canopy
The CeeLite 7500 and 11000 Kelvin panels are the first flat flexible lightbulb to contain Light-Emitting Capacitor technology. Flatline inverters maintain 99% uniform backlighting and make it possible to offer motion and/or photo sensors with external sensing jacks, while providing dimming, fading and flashing standard features.
White Light High Flux LED SourcesWhite Light High Flux LED Sources
iLED Surgery LightingThe different coloured LEDs: • provide homogeneous
spectral light distribution• adjust the colour temperature
individually for optimal contrast and differentiation.
• reducing fatigue during night operations (a higher colour temperature improves the ability to concentrate
Trumpf
iLED Surgery Lighting
The different coloured LEDs:
• provide virtually shadow free illumination up to 160,000 lx
• over 180 light fields at different depths
• multifaceted LED lights can darken certain areas of the visual field while focusing illumination on others Trumpf
Skyport is a light collecting panel that sits on your rooftop to transmit light into your home. It uses a fibre-optic wire
to send the light to specially designed 'lamps'.
The light can be transported up to 15 meters. With a 7 meter cable, the light intensity can reach 4000 lux, and
with two Skyports mounted on an angle will bring in both morning and afternoon sun
Courtesy Gomez Paz
Natural Light Collector and Fibre Optic Diffuser
Courtesy Parans
Photonic LED Textiles TurnFabric into Intelligent
Displays
by integrating flexible arrays ofmulticolored LEDs into fabrics,lighting technologies willrevolutionize the very conceptof fabric and will open up awide range of applications inthe fields of • ambient lighting,• communication, and • personal health
Courtesy Philips
That’s What’s New in Lighting
!
Roy Hughes, PEng, LC&
WarehouseASHRAE 90.1 2004 space type models
Model
Building Type % Area FCWarehouse Task 30 30
General 70 30Space Type description Wtd Avg FC 100 30
Fine Material 30
LPD =1.4
42
Model
Building Type % Area FCWarehouse Task 30 30
General 70 15Space Type description Wtd Avg FC 100 19.5
Medium/Bulky Material 19.5
LPD =0.9
43
Alternative Low & High Bay Luminaires
Courtesy: 1st Source, Sportlight, Lightedge, Metalux, Day-Brite
• Induction Fluorescent
• Compact Fluorescent
• T5HO Fluorescent• T8 or T5HO
Fluorescent• Compact
Fluorescent
Lamp Efficacy
4.2 4.56.0
4.64.3
4.7
26.2
23.322.5
10.8
0
20
40
60
80
100
120
F32
T8/7
41
F32
T8/8
41
T8 (
HP
)
F28
T5/8
41
F54
T5/H
O/8
41
MV
(4
00
W)
MH
40
0U
MS
32
0/P
S
MS
35
0/P
S
HP
S (
40
0 W
)
Mea
n L
PW
Design guide for Warehouse – 400w Metal Halide